Poka Yoke

February 25, 2021 1

 INTRODUCTION
What is a Poka- yoke?

➢Shigeo shingo defined poka-yoke as POKA- ‘Inadvertent mistake

that anyone can make’ and YOKE- ‘To prevent or proof’
➢Poka-yoke is a tool to have “zero defects” and even reduce or
eliminate quality control.
➢Poka-yoke is a Japanese name for “fool-proofing”.
➢Poke-yoke represents the intelligence of the operator by excluding
repetitive actions that require a thinking process.

February 25, 2021 2

 MISTAKE PROOFING
➢Mistake-Proofing a product's design and its manufacturing process
is a key element of design for manufacturability / assembly (DFM/A)
➢Mistake proofing is also a key element of improving product
quality and reliability

FACTORS CONTRIBUTING TO MISTAKE PROOFING:

➢Attention
➢Perception
➢Memory
➢Logical reasoning

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 PRINCIPLES OF MISTAKE-PROOFING
There are six mistake-proofing principles or methods.
➢Elimination seeks to eliminate the possibility of error by
redesigning the product or process so that the task or part is no
longer necessary.
➢Replacement substitutes a more reliable process to improve
consistency.
➢Prevention engineers the product or process so that it is
impossible to make a mistake at all.
➢Facilitation employs techniques and combining steps to make work
easier to perform.
➢Detection involves identifying an error before further processing
occurs so that the user can quickly correct the problem.
➢Mitigation seeks to minimize the effects of errors.

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2-STATUS & 3-FUNCTIONS OF POKA-YOKE

POKA-YOKE HAS 2 STATUS AND 3 FUNCTIONS:

➢Status:
1.The fault will happen or
2.The fault has happened
➢Functions:
1.Stop
2.Check or
3.Alarm

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 THREE STRATEGIES FOR ZERO DEFECT

➢Only make the product when required!

➢Make the product so it can not be used for anything else.

➢If the product is ready use it immediately.

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 POKA-YOKE CLASSIFICATION

Poka-yoke is classified into the following types:

Server Poka-Yokes Customer Poka-Yokes

Task Preparation

Encounter
Treatment Tangibles Resolution

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 PROVIDER(SERVER) ERRORS
➢Task Errors
• Doing the work incorrectly
• Doing work not requested
• Doing work in the wrong order
• Doing work too slowly
➢Treatment Errors
• Not acknowledging the customer
• Not listening to the customer
• Not reacting appropriately to the customer
➢Tangible Errors
• Failure to clean facilities
• Failure to control noise

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 CUSTOMER ERRORS
➢Preparation Errors
• Failure to bring necessary materials to the encounter
• Failure to engage the correct service
➢Encounter Errors
• Failure to remember steps in the service process
• Failure to follow system flow
• Failure to follow instructions
➢Resolution Errors
• Failure to learn from experience
• Failure to adjust expectations appropriately

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 SEVEN STEPS TO POKA-YOKE ATTAINMENT

➢Quality Processes

➢Utilize a team environment

➢Elimination of Errors

➢Eliminate the “Root Cause” of The Errors

➢Do It Right The First Time

➢Eliminate Non-Value Added Decisions

➢Implement a Continual Improvement Approach

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 POKA-YOKE APPROACH
➢Proactive Approach :
• A fully implemented ZERO DEFECT QUALITY system requires Poka-Yoke
usage at or before the inspection points during the process.
• Poka-yoke will catch the errors before a defective part is manufactured
100% of the time.
➢Reactive Approach :
• Check occurs immediately after the process.
• Can be an operator check at the process or successive check at the next
process.
• Not 100% effective, will not eliminate all defects.
• Effective in preventing defects from being passed to next process.

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Two Poka-Yoke System approaches are utilized in
manufacturing which lead to successful ZERO DEFECT
QUALITY:
1.Control Approach:
➢Shuts down the process when an error occurs.
➢Keeps the “suspect” part in place when an operation is
incomplete.
2.Warning Approach
➢Signals the operator to stop the process and correct the
problem.
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 CONTROL SYSTEM
➢Takes human element out of the equation ; does not depend on an
operator or assembler.
➢Has a high capability of achieving zero defects.
➢Machine stops when an irregularity is detected.

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 WARNING SYSTEMS

➢Sometimes an automatic shut off system is not an option.

➢A warning or alarm system can be used to get an operators
attention.
➢Color coding is also an effective non-automatic option

February 25, 2021 14

TEN TYPES OF HUMAN MISTAKES

➢Forgetfulness
➢Mis-understanding
➢Wrong identification
➢Lack of experience
➢Willful (ignoring rules or procedure)
➢Inadvertent or sloppiness
➢Slowliness
➢Lack of standardization
➢Surprise (unexpected machine operation, etc.)
➢Intentional (sabotage)
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 POKA-YOKE DEVICES
➢Poka yoke is implemented by using simple objects like fixtures, jigs,
warning devices and the like to prevent people from committing
mistakes, even if they try to!.
➢The main feature of poka-yoke devices is their exceptional
suitability for reducing or eliminating defects through effective
feedback and instantaneous corrective action.
➢These devices are capable of being used all the time by all workers;
simple and usually installed with low implementation cost.
➢Poka-yoke devices help eliminate errors and defects by giving
machines the “intelligence” to stop and signal when a error occurs.
➢Poka-yoke devices stop machines and alert workers when a
problem exists.

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 THE THREE LEVELS OF POKA-YOKE:

There are three levels at which your company can effect poka-yoke:

➢Eliminating errors defects and losses at the source or prevention

of a mistake from being committed..

➢Detection of a loss or mistakes it occurs,allowing correction before

it becomes a problem.

➢Detection of a loss or mistakes after it has occurred,just in time

before it blows up into a major issue(least effective).

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EXAMPLES OF POKA-YOKE PRODUCTS

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Snaps

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 IMPLEMENTATION IN MANUFACTURING

Poka-yoke can be implemented at any step of a manufacturing

process where something can go wrong or an error can be made.
Shigeo Shingo recognized three types of poka-yoke for
detecting and preventing errors in a mass production system:
➢The contact method identifies product defects by testing the
product's shape, size, color, or other physical attributes.
➢The fixed-value (or constant number) method alerts the operator if
a certain number of movements are not made.
➢The motion-step (or sequence) method determines whether the
prescribed steps of the process have been followed.

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 ADVANTAGES
➢They are simple and cheap.

➢They are part of the process, implementing what Shingo calls

"100%" inspection.

➢They are placed close to where the mistakes occur, providing quick
feedback to the workers so that the mistakes can be corrected.

➢Once put in place, they require minimal supervision.

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 CONCLUSION
Poka-yokes deals with understanding why people make errors
and how to analyze the process to know where errors are likely to occur
and what root causes contribute to them.
Since the poka-yoke devices detect errors at their roots n prevent
them from blowing up to become bigger problems, there is consistency
in the quality of the products, saving the cost and time spent in
subsequent quality inspection processes.

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 THANK YOU

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