Poka-yoke

Poka-yoke is a technique for avoiding simple human error in the workplace. Also known as mistake-proofing, goof-proofing, error proofing and failsafe work methods poka-yoke is simply a system designed to prevent inadvertent errors made by workers performing a process The idea is to take over repetitive tasks that rely on memory or vigilance and guard against any lapses in focus poka-yoke may save time and release the mind of worker for operations more creative and increase their value to prevent defects and errors originating in the mistake method was introduced by Shigeo Shingo in 1961 Zero Defect Quality Control three common components 1. Poka-yoke 2. source inspection 3. feedback purpose of this system be to improve the process not sort out defective parts "Set-Up Time Reduction and Mistake Proofing Methods: An Examination in Precision" list the potential benefits as:

 elimination of set-up errors and improved quality decreased set-up times with associated reduction in production time and improved production capacity simplified and improved housekeeping increased safety lower costs lower skill requirements increased production flexibility improved operator attitudes. e.g In a Quality magazine article, Melissa Larson provides interesting details about benefits resulting from the implementation of poka-yoke systems at the Supply Support Activity (SSA) at Fort Carson, Colorado, a military retail supply operation of the U.S. Army. Inventory, receipt, and batch processing all improved quantifiably Before 1. Location survey accuracy was approximately sixty-five percent prior to implementation. 2. Inventory adjustments averaged $3000 a month. 3. The rate of incorrect receipt closures to the supplier had been ninety percent. 4. Traditionally, the SSA had approximately fifteen to twenty batch processing failures per month 5. The error rate was twenty-two percent 6. Original request processing time was 12.5 days

After 1. After implementing the use of the bar-code readers location accuracy increased to ninety-eight percent. 2. Inventory adjustments dropped to an average of $250 per month. 3. The rate of incorrect receipt closures to the supplier rate dropped to zero percent. 4. there have been zero batch process failures. 5. The error rate dropped to zero percent 6. with the new request processing time is 1.6 days two approaches to implementation of Poka-Yoke method 1. control method 2. warning method