Universal design of workplaces through the use of Poka-Yokes: Case study and implications

Mi alles, C is óbal; Hol , Raimond; Ma in-Ga cia, Juan A.; Canos-Da os, Lou des A icle Uni e sal design o wo kplaces h ough he use o Poka- Yokes: Case s udy and implica ions Jou nal o Indus ial Enginee ing and Managemen (JIEM) P o ided in Coope a ion wi h: The School o Indus ial, Ae ospace and Audio isual Enginee ing o Te assa (ESEIAAT), Uni e si a Poli ècnica de Ca alunya (UPC) Sugges ed Ci a ion: Mi alles, C is óbal; Hol , Raimond; Ma in-Ga cia, Juan A.; Canos-Da os, Lou des (2011) : Uni e sal design o wo kplaces h ough he use o Poka-Yokes: Case s udy and implica ions, Jou nal o Indus ial Enginee ing and Managemen (JIEM), ISSN 2013-0953, OmniaScience, Ba celona, Vol. 4, Iss. 3, pp. 436-452, h ps://doi.o g/10.3926/jiem. 4n3.p436-452 This Ve sion is a ailable a : h ps://hdl.handle.ne /10419/188462 S anda d-Nu zungsbedingungen: Die Dokumen e au EconS o dü en zu eigenen wissenscha lichen Zwecken und zum P i a geb auch gespeiche und kopie we den. Sie dü en die Dokumen e nich ü ö en liche ode komme zielle Zwecke e iel äl igen, ö en lich auss ellen, ö en lich zugänglich machen, e eiben ode ande wei ig nu zen. So e n die Ve asse die Dokumen e un e Open-Con en -Lizenzen (insbesonde e CC-Lizenzen) zu Ve ügung ges ell haben soll en, gel en abweichend on diesen Nu zungsbedingungen die in de do genann en Lizenz gewäh en Nu zungs ech e. Te ms o use: Documen s in EconS o may be sa ed and copied o you pe sonal and schola ly pu poses. You a e no o copy documen s o public o comme cial pu poses, o exhibi he documen s publicly, o make hem publicly a ailable on he in e ne , o o dis ibu e o o he wise use he documen s in public. I he documen s ha e been made a ailable unde an Open Con en Licence (especially C ea i e Commons Licences), you may exe cise u he usage igh s as speci ied in he indica ed licence. h ps://c ea i ecommons.o g/licenses/by-nc/3.0/ JIEM, 2011 – 4(3):436-452 – Online ISSN: 2013-0953 – P in ISSN: 2013-8423 h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 436 - Uni e sal design o wo kplaces h ough he use o Poka- Yokes: Case s udy and implica ions C is óbal Mi alles1, Raymond Hol 2, Juan A. Ma in-Ga cia1, Lou des Canos-Da os1 1ROGLE-Dep o. de O ganización de Emp esas. Uni e sidad Poli écnica de Valencia (SPAIN) 2School o Mechanical Enginee ing. Uni e si y o Leeds (UK) [email p o ec ed]; [email p o ec ed]; jama [email protected] .es; louc[email p o ec ed]p .es Recei ed June 2010 Accep ed Sep embe 2011 Abs ac : Pu pose: Employmen plays an impo an pa in many people’s li es beyond me ely p o iding income, since con inued pa icipa ion in wo k can ha e many he apeu ic bene i s o wo ke s de ined as disabled. Howe e , disabled wo ke s ace a ange o ba ie s o employmen , despi e legisla ion in ended o imp o e wo kplace accessibili y emphasizing adap a ions o he wo kplace, which many employe s o en ind di icul and expensi e. The Poka-Yoke app oach was de eloped in he manu ac u ing indus y as a way o imp o ing p oduc i i y by educing e o s using o en e y simple adap a ions. This pape a gues ha , as Poka-Yokes a e designed o make li e easie and imp o e he pe o mance o wo ke s wi hou impai men s, hey a e close o he philosophy o Uni e sal Design han o Accessible Design, and o e an easy and inclusi e way o making wo k mo e accessible o all kind o wo ke s. Design/me hodology/app oach: This pape p o ides a case s udy demons a ing he use o he Poka-Yoke app oach in a shel e ed wo k cen e o disabled; highligh ing how hey se ed o imp o e accessibili y o wo k by ul illing Uni e sal Design p inciples. Findings: Ou esea ch allows us o demons a e he g ea po en ial o Poka-yokes o gaining accessibili y o he wo kplace. The eal applica ion o his app oach, Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 437 - bo h in shel e ed wo k cen es and o dina y companies, can con ibu e o imp o e he high unemploymen a es o disabled people. Resea ch limi a ions/implica ions: The p oposal is inno a i e and was applied in one speci ic company. Thus, a ange o cus omized Poka-yokes would be desi able o di e en indus ial sec o s. P ac ical implica ions: Manage s o shel e ed wo k cen es, and also o o dina y companies, can ealize abou he g ea po en ial o Poka-Yokes as an easy means o gaining lexibili y and accessibili y. O iginali y/ alue: The e a e e y ew pape s ela ing lean manu ac u ing ools and disabili y. Ou app oach analyzes he bene i s o his app oach o he labou in eg a ion o disabled people. Keywo ds: lean p oduc ion, high in ol emen wo k p ac ices, shel e ed wo k cen e s 1 In oduc ion Wo k plays a cen al ole in he majo i y o adul li es a many socioeconomic le els. I main ains income and con ibu es o indi idual iden i y and social s a us. The e is eme ging e idence ha con inued pa icipa ion in a wo k ole has he apeu ic bene i s. F om he poin o iew o employmen , he e m “disabled pe son” e e s o hose people whose oppo uni ies o ob ain and main ain a sui able job and o p og ess wi hin ha job a e ema kably lowe han he gene al popula ion due o a men al o physical de iciency (Lopez Pino e al., 2005). O e he las h ee decades, he legal amewo ks and egula ions o he disabled ha e been signi ican ly modi ied. Many go e nmen s ha e implemen ed policies aimed a p omo ing he igh o he disabled o in eg a e as ully as possible in o socie y. In his sense, social and employmen in eg a ion o he disabled has ecei ed special a en ion in mos in e na ional egula ions, e.g. he Uni e sal Decla a ion o Human Righ s, he Cha e o he nine een eigh ies om Rehabili a ion In e na ional, he P og am o Wo ldwide Ac ion om he UN in 1988, o he Eu opean Social Cha e in 1981. In iew o he abo e, a ious a emp s a e being made o u he he in eg a ion o hese ci izens in socie y. Se e al coun ies deal wi h his p oblem h ough di e en Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 438 - in eg a ion app oaches and he awa eness ega ding his issue goes beyond he public and go e nmen al sphe es. Indeed, unde he concep o Co po a e Social Responsibili y (CSR), an inc easing numbe o companies a e becoming conce ned wi h his ma e (Ko le & Lee, 2005). Since 1990, Social Responsibili y has ound inc easing in e es in he li e a u e. Al hough in ce ain o ums he e a e doub s as o whe he his boom is jus a passing end, ce ain indica o s e eal ha we a e acing a eal change o pa adigm in which companies a e seen as esponsible o some hing mo e han me ely ob aining maximum p o i (Gu hey e al., 2006). In his scena io, he employmen o disabled wo ke s is seen as a way o including he in e es s o socie y in he company goals. In ac , wo k in he compe i i e wo k o ce may be a signi ican sou ce o enhancing adap i e skills o people wi h disabili ies and, hus, g ea ly adding o he success o communi y li ing and socio- labou in eg a ion (S ephens e al., 2005). In his sense, he second global epo 2007 abou Disc imina ion p esen ed as pa o he In e na ional Labou O ganiza ion Decla a ion ela i e o he undamen al wo kplace p inciples and igh s (ILO 2007), sugges s ha go e nmen s and companies adop non legisla i e egula ions (no as social wellbeing policies, bu as a ques ion o human igh s and social in eg a ion). Addi ionally i p oposes ha he ac i e policies, ac ions and p og ams abou labou ma ke s should comba he disc imina ion o wo ke s wi h disabili ies in h ee ways: (1) Via he o mula ion o policies and egula ions agains disc imina ion in he wo kplace; (2) Via an inc ease in he oppo uni ies o people liable o being disc imina ed o ind a job; (3) Via an imp o emen o he hi ing p ocedu es in public and p i a e sec o s (Mi alles e al., 2010). Bu despi e he g ea legisla i e e o s made by mul iple na ional and in e na ional ins i u ions, o al social-employmen in eg a ion o people wi h disabili ies s ill seems a away. This ac con i ms he pe cep ion ha he solu ion has o come no only om legal egula ions ia go e nmen al measu es, bu also by o e coming he p ejudices abou he capabili ies o he disabled, and by he genuine commi men o companies o include in eg a ion p og ams in hei ope a ion s a egies and models. Fu he mo e, he inco po a ion o disabled people o many p oduc i e ac i i ies gene a es added alue o a company, as well as socie y as a whole, which is pa icula ly imely gi en he cu en pensions c isis and ageing popula ion. 1.1 Aim and s uc u e o he pape Mi alles e al. (2010) analyzed he global bene i s o ce ain Ope a ions Resea ch/Managemen Science ools ha , i applied co ec ly, ha e a posi i e impac on accessibili y o wo k. Following his a gumen a ion, his pape aims o Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 439 - show he g ea po en ial o one o he ools p esen ed in Mi alles e al. (2010): he Poka-Yokes. I will be demons a ed how his managemen ool, ini ially designed o minimize e o s and maximize p o i , also helps o achie e social-employmen in eg a ion in he mos e icien possible manne , hus allowing he inco po a ion o CSR p ac ices in companies. The s uc u e o he a icle is as ollows: in he nex sec ion, a li e a u e e iew shows he di e ences be ween Uni e sal Design and Inclusi e/Accessible Design and s a es he philosophy o he p oposed app oach. Then a e iew on he Poka- Yokes and i s po en ial is discussed. Sec ion 3 shows a case s udy whe e his app oach was implemen ed wi h success in i e di e en wo ks a ions, each one applying di e en Poka-Yokes. Finally, Sec ion 4 discusses he esul s achie ed in he case s udy and Sec ion 5 summa izes he gene al conclusions and he u he esea ch p oposed. 2 Li e a u e e iew This sec ion e iews li e a u e on he wo main hemes o he pape : Uni e sal Design and he wo kplace; and Poka-Yokes which migh help o achie e his. 2.1 Uni e sal Design and he Wo kplace In many coun ies, a ange o legisla ion o imp o e employmen among he disabled has been enac ed, such as he Ame icans wi h Disabili ies Ac (ADA) o he Disabili y Disc imina ion Ac (DDA) in he UK. Bell and Hei muelle (2009) a gue ha , a om imp o ing employmen a es among he disabled, bo h he ADA and DDA may ha e wo sened i , due o he inc eased cos bu den placed on employe s. The iew e lec ed in his legisla ion is one ha Sai o (2006) de ines as Accessible Design, o special adap a ions o accommoda e wo ke s wi h disabili ies so ha ba ie s o access a e elimina ed. While in p inciple his a laudable aim, many companies, e en wi h he ins i u ional help hey may ecei e, canno a o d i , pa icula ly gi en he highe absen eeism o disabled wo ke s due o heal h p oblems, which can lea e expensi e adap ed wo kplaces s anding emp y (Mi alles e al., 2007). Special adap a ions can also be a sou ce o esen men among non- disabled colleagues (Cle eland e al., 1997); educe Quali y o Li e by calling a en ion o he o he ness o a disabled wo ke (Lemai e & Mallik, 2008); and companies o en pass on he cos o adap a ion o disabled wo ke s in he o m o lowe wages (Jones & La eille, 2010). Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 440 - Sai o (2006) highligh s Uni e sal, o Inclusi e, Design as an al e na i e o he Accessible Design philosophy embedded in cu en legisla ion. Uni e sal Design seeks o a oid he need o special adap a ions by designing p oduc s and en i onmen s ha can be used by he la ges p opo ion o he popula ion possible. This app oach emphasises capabili y a he han disabili y, a guing ha disabili y and exclusion a ise om poo design, and ha design which equi es a low capabili y h eshold bene i s e e yone, no jus he disabled (Cla kson e al, 2003). In his sense Uni e sal Design is ocused on se en co e ene s (Cen e o Uni e sal Design, 1997): • Equi able use: The design is use ul and ma ke able o people wi h di e se abili ies. • Flexibili y in use: The design accommoda es a wide ange o indi idual p e e ences and abili ies. • Simple and in ui i e use: Use o he design is easy o unde s and, ega dless o he use ’s expe ience, knowledge, language skills, o cu en concen a ion le el. • Pe cep ible in o ma ion: The design communica es necessa y in o ma ion e ec i ely o he use , ega dless o ambien condi ions o he use ’s senso y abili ies. • Tole ance o e o : The design minimizes haza ds and he ad e se consequences o acciden al o unin ended ac ions. • Low physical e o : The design can be used e icien ly and com o ably, and wi h a minimum o a igue. • Size and space o app oach and use: App op ia e size and space is p o ided o app oach, each, manipula ion, and use, ega dless o he use ’s body size, pos u e, o mobili y. In p ac ice, i is ecognized ha he di e si y o he human ace makes uly Uni e sal Design i ually impossible, and ha some deg ee o design exclusion is ine i able, bu ha his should be kep o a minimum as a as possible (Cla kson e al., 2003). This pape akes Uni e sal Design as i s co e philosophy. The a gumen is no ha he e should be elimina ed bu ha , so a as possible, adap a ions should be designed o bene i as many wo ke s as possible, ega dless o disabili y. The e is a su p ising lack o li e a u e in his a ea: whe eas esea ch Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 441 - g oups such as he Helen Hamlyn cen e (Mye son e al., 2009) a e making in oads in o inclusi e wo kplace design, hei ocus is on he design o he wo k en i onmen and no on he design o he wo k i sel . 2.2 Poka-Yoke The Poka-Yoke (a Japanese wo d ha means mis ake-p oo ing) echnique was i s de eloped in 1961 by Shigeo Shingo. Poka-Yoke uses de ices on p ocess equipmen o p e en he human o machine e o s ha esul in de ec s, o o inexpensi ely inspec each i em p oduced o de e mine whe he i is accep able o de ec i e. Poka-Yoke-designed manu ac u ing de ices a e one o he bases o Shingo’s ze o quali y con ol concep s, which means ha he de ec a e in a p oduc ion sys em is ze o. Poka-Yoke design can d ama ically dec ease he isk o p oducing de ec i es p oduc s (Shingo, 1986). The Poka-Yoke philosophy also aims o make wo k easie and p e en e o s caused by mono ony o o he p ocess- ela ed causes. In many p oduc i e en i onmen s, he e is a endency o equa e speed wi h p oduc i i y. T adi ional enginee ing p ocesses a e designed o inc ease he e iciency o an ope a ion by enabling people and machines o wo k as e , and p ocesses a e usually complica ed o achie e g ea e speed; ye i is hese complica ions which cause many o he e o s people and equipmen make, esul ing in mo e de ec i e p oduc s. By con as , he Poya-Yoke philosophy aims o inc ease p oduc i i y by simpli ying p ocesses, making hem mo e e icien , educing he numbe o e o s ha need o be co ec ed, and inc easing he o e all e iciency o he sys em. Poka-Yoke can be used whe e e e o s can occu and can be applied o any ype o p ocesses and helps wo ke s o be “ igh i s ime”, enhancing he quali y o he p oduc and he o e all ou pu o he p ocess. Poka-Yoke suppo s e o s o elimina e was e caused by: o e p oduc ion, in en o y, wai ing, anspo a ion, mo ion, o e p ocessing, quali y de ec s, ep io i iza ion and also was e caused by people's skills. Mos impo an ly, Poka-Yoke was de eloped wi h he aim o making wo k easie o wo ke s wi hou disabili ies, and as such demons a e he alue o o en simple adap a ions ailo ed o he job a hand. I is o en assumed ha adap a ions o suppo he di e si y o si ua ions aced by disabled wo ke s p esen a huge challenge o designe s. In ac , he ex a in ellec ual e o needed o o e come disabili y o en esul s in a be e inal design o bo h he disabled and non-disabled use s. In his pape , we a gue ha Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 442 - Poka-Yoke ep esen s a sui e o simple and ela i ely inexpensi e ways o imp o ing access o wo k and he p oduc i i y and pe o mance o disabled and non-disabled wo ke s, and a powe ul ool o implemen ing Uni e sal Design in he wo kplace. 3 A ep esen a i e case s udy This sec ion will desc ibe a case s udy whe e he po en ial o Poka-Yokes as a means o wo k in eg a ion is demons a ed. The case s udy was de eloped in a Shel e ed Wo k Cen e o he Disabled (hence o h SWD) close o he ci y o Valencia (Spain) ha assembles di e en kinds o p oduc s. SWD a e a model o socio-labou in eg a ion ha ies o mo e away om he adi ional s e eo ype ha conside s disabled people as unable o de elop con inuous p o essional wo k. Like any o he p i a e i m, a SWD compe es in eal ma ke s and mus be lexible and e icien enough; he only di e ence being ha hei s a mus ha e 70% o wo ke s wi h some kind o disabili y. The SWD in his case s udy assembles and packages elec ical/elec onic de ices and me al/plas ic p oduc s, and aking on any oppo uni ies ha become a ailable in he ma ke . Al hough he company once employed mo e han 160 wo ke s, c isis has o ced i o educe i s s a o 92 wo ke s, whe e 82 su e some kind o disabili y; including some 40% wi h physical disabili ies, abou 55% o hem wi h some men al disabili y, and he emaining 5% wi h some cogni i e impai men . The company's main deals come om big in e na ional companies, who con ac he SWD se ices o assembling ce ain p oduc s. The SWD usually ecei es aw ma e ial and componen s om i s supplie , and e u ns he assembled p oduc . Ful illing he clien 's equi emen s in bo h cos and quali y a e c i ical o ecei ing u u e o de s. Only by a pe o ming well can he SWD ge new con ac s o new p oduc s, and po en ially p o ide mo e jobs o he disabled. In ac , his labou in eg a ion o mula has been e y success ul in dec easing he o me e y high unemploymen a es o he Spanish Disabled. Despi e his, i is in con en ional companies whe e he ue social–employmen in eg a ion o he disabled should ake place: while SWDs e ec i ely p o ide e y necessa y wo k o hese people, hey do no con ibu e so much o socie al no maliza ion (Mi alles e al., 2010). I is impo an o ecognise ha his case s udy was de eloped in a SWD because i p o ided access o a di e se wo k o ce o he pu pose o ou expe imen a ion: ou long e m goal is o demons a e he po en ial o Poka-Yokes o labou in eg a ion in o dina y companies. Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 443 - 3.1 Ini ial si ua ion Ini ially, he SWD used indi idual wo kplaces, designed wi hou any pa icula conside a ion o disabili ies, so ha only a ew employees could comple e he en i e assembly p ocess o mos o he p oduc s e icien ly. Mos wo ke s we e e icien in some s eps o he assembly p ocess, bu had di icul ies wi h one o mo e ope a ions, which made hei quali y yield and hei e iciency low. Fo wo ke s wi h men al disabili ies i was e en mo e di icul , since mos o he assembly p ocesses also included jobs ha equi ed high concen a ion and/o capabili ies ha hey lacked. Consequen ly, he SWD could only assign a subse o asks o each indi idual acco ding o his/he limi a ions, esul ing in a low lexibili y o he wo k o ce whe e he SWD was no able o adap o demand luc ua ions o new equi emen s om clien s. In many cases, he SWD was unable o capi alise on inc eased demand o a clien 's p oduc , due o he lack o lexibili y in i s wo k o ce. 3.2 Focus o he esea ch In o de o es he alidi y o ou p oposal, he SWD's u ni u e assembly & packaging sec ion, wi h a s a o wen y wo ke s, was analyzed. The capabili ies and limi a ions o e e y wo ke we e s udied using bimanual analysis and lea ning cu es (Smun and Wa s, 2003) o e alua e hei lexibili y and loca e possible incompa ibili ies wi h he equi ed assembly asks a each wo ks a ion. The i e wo ks a ions wi h mos incompa ibili ies we e selec ed o use as a pilo s udy. Twel e o he wen y wo ke s had di icul y wi h he asks a one o se e al o he i e wo ks a ions. N . Kind o disabili y WS1 WS2 WS3 WS4 WS5 1 Men al 2 Men al 3 Men al 4 Men al 5 Men al 6 Men al 7 Men al 8 Men al 9 Men al 10 Men al/Physical 11 Physical 12 Physical Table 1. Ini ial si ua ion o he i e wo ks a ions analyzed Focusing on hese wel e wo ke s we go he ini ial da a in Table 1, whe e he shaded cells ep esen he ac ual possible wo k assignmen s, and he non-shaded Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 450 - in es men in he wo k o ce, wi h imp o ed e iciency helping o co e he cos s o implemen a ion. In ac , in his case s udy he o al implan a ion cos was ex emely low compa ed o he high imp o emen , bo h in p oduc i i y and lexibili y, o he whole u ni u e assembly & packaging sec ion. To conclude i has o be no ed ha Poka-Yoke me hod was o iginally de eloped o use in a manu ac u ing en i onmen , and ha is he con ex in which i has been applied he e. Howe e , he Poka-Yoke app oach has ound implemen a ion in a ange o en i onmen s, and i s po en ial o implemen ing Uni e sal Design p inciples in o he ypes o wo k should be conside ed. 5 Conclusions and u he esea ch This pape has illus a ed ha Poka-Yokes a e a po en ial ool o implemen ing Uni e sal Design in he wo kplace, he co e bene i being ha - by inc easing he ease o a ask - hey o e bene i s o all wo ke s, no jus hose wi h disabili ies. I is impo an o ecognise ha his app oach does ha e limi a ions: as Table 2 illus a es, while access was imp o ed, he Poka-Yokes in oduced could no make all asks accessible o e e y wo ke , emphasising Cla kson e al. (2003) poin ha o al inclusion is di icul and minimising exclusion is a mo e ealis ic aim. Ha ing es ablished he po en ial o Poka-Yokes as a ool o imp o ing wo kplace inclusion, he key challenge is in de eloping ways o making his app oach easy o implemen wi hou he need o specialis expe ise. Fu he esea ch will be concen a ed on wo a eas: on he one hand, being able o es ima e how a gi en Poka-Yoke will impac inclusion a es (one clea op ion is o adap he Camb idge Uni e si y’s Exclusion Calcula o (Cla kson e al., 2003)). On he o he hand, o design a p ac ical me hodology ou lining he s eps a company should ake o de elop and deploy app op ia e Poka-Yoke in he wo kplaces. Acknowledgmen s The au ho s would like o acknowledge he unding o he Resea ch Suppo P og am PAID-00-10 o Uni e si a Poli ècnica de València. They also would like o acknowledge he SWD in ol ed in his esea ch. Jou nal o Indus ial Enginee ing and Managemen - h p://dx.doi.o g/10.3926/jiem.2011. 4n3.p436-452 - 451 - Re e ences Bell, D., & Hei muelle , A. (2009). The Disabili y Disc imina ion Ac in he UK: Helping o hinde ing employmen among he disabled?. Jou nal o Heal h Economics, 28, 465–480. h p://dx.doi.o g/10.1016/j.jhealeco.2008.10.006 Cen e o Uni e sal Design (1997). 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