Goutam Kumar

PIBM, Pune
prese
nt
POKA-
POKA-
YOKE
YOKE
Toyota 1st
car
 History
The term poka-yoke was applied
byShigeo Shingos in the 1960s

1919 to
1991
Poka-yokeis a Japanese word
that means "fail-safing" or
"mistake-proofing".

A poka-yoke is any
mechanism in alean
manufacturingprocess that
helps an equipment operator
avoid mistakes .

Its purpose is to eliminate

product defects by
Poka-Yoke was developed by Shigeo
Shingo from Toyota Motor as a tool to
achieve Zero Defects.

The process of Zero Defects is also

known as Mistake Proofing or Fail-
Safe.
 Old types Lift
Set by engineer
in a building
&
Its maximum
weight capacity
is 200 kg
 Lift
capacity=People
weight

Weight
50kg

Weight
60 kg

Weight
90 kg
Total lift
capacity
=200
 If more
people enter
the lift then
weight will
increase,
which
increases
the
possibility of
break down
of lifts wire
because
there is no
warning
mechanism
on excess
weight .
Latest lifts are
very advanced,
because when it
is over weight
the alarm will
start & indicate
light , until
weight is not
reduced This is
done through
poka yoke
 Lift
move
without
any
fault.
 Here
people want lift but
he /she cant use ,
why ?
Because lift cant run
on overload. People
want but they cant
use. This is good for
our safety, so here
no any defect comes
out .
This is also called
zero defect.
Key principle
Error is inevitable but can be
eliminated
Before Poka yoke After Poka yoke
Where
I put
my
keyboa
rd
cable ?
??
To achieve quality, it
has to be designed
into the product
If I want to build
good quality product
we should use good
quality material.
 Mistake provides an
AAA,
Next opportunity for
time I
will not improvement and error
do
Mishaps/error/problem/crisis are the
results of inadvertent negligence of
small little things(small things) by
some one in the chain.
Cent percent inception deployed at the
end-of-the line cannot solve the
problem of defects
 Cent percent inception
cannot ensure 100
percent quality
1ST
GENRATION 2ND
COMPUTER GENRATION
COMPUTER
3RD
GENRATION 4TH
COMPUTER GENRATION
COMPUTER
The faster we discover the
problem, the easier and less
expensive it is to correct it.
Characteristics of
poka yoke
 Poka yoke
inexpen simpl proofing is
sive e powerful
because its
every part is
connected to
a digital
signal so
when any
fault is
found signal
is passed

Fail safe machine comprehen

for quality control sive
Advantage of poka-
yoke
Element rejection and
rework.
Reduce transport,
handling, and
rerouting of job.
 Lets Free a persons mind
take a
tea from maintaining
break repetitive vigil.
where I
am at
fault?
Build
up
moral
on
the
floor
Creates extra capacity
which is otherwise
wasted due to rework
and rejection
Improve productivity
of the process
Than
ks