1 – Definition

A poka-yoke is a simple and reliable device that physically prevents:

9 either the error leading to the defect
9 or the transmission of the defect to the next workstation

Of course, not producing the defect in the first place is always preferable to detecting the
defect afterwards. (An once of prevention is worth a pound of cure, as they say.)

There are two types of poka -yoke:

9 Product: based on inherent product characteristics such as shape or symmetry
9 Process: based on certain product characteristics in order to avoid errors in the
manufacturing process.

The poka-yoke must be permanent .

The poka-yoke must be “foolproof” (i.e. it must be impossible to bypass).

Only an authorized person (e.g. Gap Leader, Supervisor) may intervene.

Situations to avoid: - reset button
- master key
- simple disconnection (e.g.from electrical outlet)

The poka-yoke must be foreseen upstream, right from the product/process design phase.

Examples of poka-yokes in everyday life:

3.5” diskettes can not be inserted upside down because one corner is cut. If the cut corner
is on the wrong side, it hits something and the diskette will not go all the way in.
In an ATM (cash dispenser), you have to remove your credit card before you can get your
money. This prevents you from forgetting your card in the machine.

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