POKA-YOKE

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 WHAT IS POKA-YOKE?

 It is a Japanese Term which means “Mistake Proofing”

It was originally known as Baka-Yoke, Which means

“Fool Proofing”

It is mostly used in manufracturing Sectors.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.
 HISTORY
The term “poka yoke” was coined by Shigeo
Shingo, a key contributor to the Toyota
Production System (TPS), in the 1960s. ... Shingo
originally called the technique “baka-yoke,” or
“idiot-proofing,” but changed it to the milder
“poka yoke,” or “error-proofing,” after an
operator became offended.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 What is Error?

Error is a Deviation from the what is correct,

Right or True
Previously it was prevented by scolding,
Retraining or Telling them to be more careful
Now it was prevented by training &
motivation.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 TYPES OF ERROR
 Forgetfulness
 Miss-Understanding
 Wrong Identification
 Lack of Experience
 Slowliness
 Lack of Standardization
 Surprise

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 PRINCIPLES OF POKA YOKE
 Elimination:- Seeks to eliminate the possibility of
error by redesigning the product or process.
 Replacement:-Substitutes a more reliable process to
improve consistency
 Prevention:-Product or process to be prevent from
possibility of mistake
 Detection:-employee technique and combining steps
to make work easier to perform
 MITIGATION

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 WHY POKE-YOKE REQUIRED?

 For operational Excellence

Can prevent errors from occurring in the first
place.
To eliminating Defects in the process as early
as possible.
To ensure the proper condition exist before
actually executing the process step.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 WHAT ARE THE STATUS OF POKA YOKE

STATUS:-

 The fault will happen or

 The Fault will happened

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 WHAT ARE THE FUNCTION OF POKA YOKE

FUNCTIONS:-

 STOP

 CHECK

 ALARM

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 THREE LEVEL OF POKA-YOKE
THERE ARE THREE LEVELS AT WHICH AN ORGANISATION
CAN EFFECT POKA YOKE:

 Eliminating error defect and losses at the source or

prevention of a mistake from being committed
 Detection of a loss or mistake it occurs, allowing
correction before it become a problem
 Detection of loss or mistake after it has occurred,
just in time before it blows up into a major
issue(least effective)
NOV-22, 2021 Allied JB Friction Pvt. Ltd.
 POKA YOKE DEVICES
 Poka yoke is implemented by using of simple object like
fixture, jig, warning devices and the like to prevent people
from committing mistakes, even if they try to do!
 The main feature of poka yoke device is their exceptional
suitability for reducing or eliminating the defect through
effective feedback and corrective action.
 These devices are capable of being used for all the time by all
worker, simple and usually installed with low implementation
cost
 Poka yoke device is capable to stop the machine or alert the
worker when problem exist.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 CONCLUSION

Poka-Yoke deals with understanding why people make errors and

how to analyze the process to know where error are likely to
occur and what root cause contribute to them

Since the poka-yoke devices detect errors at their root and

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.

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

Examples of Poka-yoke used in our daily life:
•Computer spell checker
•Drop down box in a database
•Gas cap attached to a car
•Bar code for correct product identification
•Seatbelt buzzer to warn drivers

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 Examples of Poka-yoke

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

 Examples of Poka-yoke

NOV-22, 2021 Allied JB Friction Pvt. Ltd.

THANKS