Poka Yoke

(Mistake Proofing)

The concept of Poka Yoke (Mistake Proofing) has its origin in the zero defect concept which is a
part of the TPM philosophy. Whereas, the focus of zero defects is to achieve an ideal of zero
defects in the parts produced (in manufacturing organization) or zero defects in the processes
employed in a service organization, Poka Yoke focuses on eliminating the defects of human
origination by reducing the opportunity for defects.

Defects of Human Origin

Defects of human origin occur due to simple mistakes or errors committed by human beings who
are operating the process. These errors are not committed purposely but are, due to any of the
following reasons:

™ Forgetfulness
™ Misunderstanding
™ Wrong identification
™ Lack of experience
™ Ignoring rules or procedures
™ Sloppiness
™ Slowness
™ Hurry
™ Lack of standardization
™ Surprise

Apart from errors due to mistakes, certain defects are also produced due to intentional sabotage.
The focus of Poka Yoke is to eliminate these defects.

Guidelines for Poka Yoke

The following are the guidelines for implementing Poka Yoke:

1) Quality Processes – Design, Robust, Quality Processes to achieve zero defects.

2) Involve all employees in the process to leverage their knowledge and experience
3) User systematic problem solving methodology to eliminate errors
4) Eliminate the root casts. Use the 5 Ws and 1 H approach.
5) Do it right the first time
6) Eliminate non-value added decisions. (Decisions should directly address the problem)
7) Implement increamentally (do not expect 100% results in the first attempt.)
Poka Yoke Implementation

In implementing Poka Yoke, we use sensors or other devices to catch errors that may pass the
human operators or inspectors. Broadly two approaches are used in implementing Poka Yoke.

Control Approach

In the control approach, the process is shut down when the error occurs.

Warning Approach

In the Warning Approach a signal is given to the operator or inspector, when an error occurs, so
that he can appropriate action

Methods of Poka Yoke

There are three primary methods used in implementing Poka Yoke :

1. Contact Method
2. Counting Method
3. Motion sequence method

Each of these methods can be used in a control approach or a warning approach.

Contact Method

In the Contact Method, a sensing device is used to detect whether the part or object is meeting
the requirement of the process. Sensors such as, limit switches, guide pins, guide blocks, toggle
switches, photoelectric switches, load cells etc., are used in this method. Apart from sensors, the
design of the part or component, itself may be made in such a way, as to preclude the use of the
wrong part or components.

Counting Method

In the counting method, the number of parts or components required to complete the operation
are counted to ensure that the exact number of parts are used. In this method, physical sensors
such as guide pins, photoelectric sensors etc., are used.

Motion Sequence Method

In the Motion Sequence Method, the sensors are used to determine if a motion or step in a
process as occurred. If the step has not occurred, or occurred out of sequence, the sensor signals
a timer or other device to stop the machine or signal the operator.
Some examples of Poka Yoke Devices:

™ Dowel and locating pins

™ Error and alarm detectors
™ Limit or touch switches
™ Meters and counters
™ Vibration detectors
™ Photoelectric sensors
™ Pressure sensors
™ Fibre optic sensors
™ Warning lights
™ Colour indicators
™ Noise detectors

B. Girish, Dy. Director,

National Productivity Council, Chennai