Poka-Yoke

Shingo advocates the concept of zero quality control by arguing that

inspection processes or the use of statistical control should be
completely eliminated.

He believes that quality should be controlled at the source of the

problem and not after the problem has manifested itself.

He recommends that inspection should be incorporated within the

process and at the point where the problem has been identified and
from where it should be eliminated.
Poka-Yoke

He considers that statistical quality control tends to focus on the effect

(subsequent errors related to operators), rather than the cause which is
due to process imperfections and abnormalities.

He is the developer of a concept called ‘Poka-Yoke’ which means

foolproofing. A Poka-Yoke device or system is one that prevents
incorrect parts from being made or assembled or easily identifies any
flaw or error.
Poka-Yoke - Principles

■ Control upstream, close to the source of problem by for example

incorporating monitoring devices to warn on defects in materials or
abnormalities within the process.

■ Establish control mechanisms to deal with different problems to enable

operators to know which problem to cure and how to cure it with
minimal disruption to the operating system.
Poka-Yoke - Principles…contd.

■ Take a step-by-step approach by taking small strides, simplifying

control systems and having economic viability in mind. Efficiency,
technological sophistication, available skills, work methods have all got
to be carefully studied for effective use of Poka-Yoke.
Poka-Yoke - Principles…contd.

■ Do not delay improvement by overanalyzing. Although many

manufacturers main objective is to achieve closeness between design
manufacturability, many Poka-Yoke ideas can be implemented as soon
as the problems have been identified with no cost at all to the
companies concerned.

■ Poka-Yoke encourages inter-departmental co-operation and is main

vehicle for continuous improvement because it encourages continuous
problem-solving activity.

Note: See mistakeproofing in this section