Poka Yoke

implementation

Pritpal Singh Chohan BOS

(15-03-2014)
 (Developed by Dr. Shigeo Shingo)

POKA YOKE
“Poka Yoke” means “Fail safing” or “Mistake
proofing”
‘YOKE’RU is TO AVOID
‘POKA’ is INADVERTENT MISTAKES
(Mistakes by chance)
Source inspection

• These techniques reduce the defect rate.

• Do not eliminate the error(s).
• Causal relationship between errors and defects.
• If the error source is eliminated, errors will never become
defects.

Error Defect Information Error Information

Feedback Feedback

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Lets discuss a simple example

Pictures speak a thousand words.

Everyday examples of Poka Yoke:
 What causes defects ?

1.Inappropriate procedures or standards

2.Excessive variability happens during actual operations
3.Damaged or excessively variable materials
4.Worn machine parts (for example, bearings or tools)
5.Human mistakes

The fact is, human beings are very forgetful and tend to make
mistakes. Too often we blame people for making mistakes.
Especially in the workplace, this attitude not only discourages
workers and lowers morale, but it does not solve the problem.
POKA YOKE is a technique for avoiding simple human error at
work.
10 different types of errors where a Poka Yoke applied will help against
cumbersome safeguards :

Forgetfulness ; Sometimes we forget

things when we are not concentrating.
Safeguards : Alerting operator in advance
or checking at regular intervals

Errors due to misunderstanding ;

Sometimes we make mistakes when we
jump to the wrong conclusion before we're
familiar with the situation.
Safeguards : Training, checking in
advance, standardizing work procedures.
Willful errors ; Sometimes errors
occur when we decide that we can
ignore rules under certain
circumstances.
Safeguards : Basic education and
experience.

Inadvertent errors ; Sometimes

we are absentminded and make
mistakes without knowing how they
happened.
Safeguards : Attentiveness,
discipline, work standardization.
  Error in identification ; Sometimes
we misjudge a part for assy.
Safeguards : Training, attentiveness,
vigilance

Errors made by amateurs ; Sometime

we make mistakes through lack of proper
experience.
Safeguards : Skill building, work
standarization.
Errors due to slowness ;
Sometimes we make mistakes
when our actions are slowed down
by delays in judgment.
Safeguards : Skill building, work
standarization.

Errors due to lack of

standards ; Some errors occur
when there are no suitable
instructions or work standards.
Safeguards : Work
standaridization, work
instructions.
 Surprises errors ; Errors
 

sometimes occur when

equipment runs differently than
expected.
Safeguards : Total productive
maintenance (TPM) , work
standarization.

Intentional errors ; Some

people make mistakes
Mindset & attitude deliberately, crimes and sabotage
should be changed are example.
by training Safeguards : Fundamental
education, mindset training with
positive thinking, discipline.
 Human Errors That Lead To
Potential
1. Forgetfulness Prevention
2. Key Xto Variation
Errors due misunderstanding
3. Errors in identification
4. Errors made by untrained workers
Detection in
5. Willful errors (ignore rules) Process:
6. Inadvertent errors (distraction, fatigue)
7. Errors due to delay in decision making
8. Errors due to lack of standards
Detection After
9. Surprise errors (malfunctions) Mistake:
10. Intentional errors (sabotage)

Also consider Mistake Proofing against these having any

impact on your Key Xs.
 Evolution Of Defectives And Application
Of Mistake Proofing

ERRORS DEFECTS DEFECTIVES

Prevention Detection in Detection After

Process: Mistake:
• Elimination • Catch errors • Detect
of issues at during defects
the source, processing before they
or before move to
prevention becoming a next step
of errors problem
from
occurring

Best Good
(prevention) (detection)
Poka-Yoke design methodology

• Three suggested methods.

• Weight, the dimensions or the shape.

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Poka-Yoke design methodology

• The use of meters/counters, spare pieces method or

a fixed sequence in the assembly process

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 Poka-Yoke design methodology

• Use technology to design the

Poka-Yoke devices.
• Contact mechanisms.
• Limit switches.
• Mechanisms without contact.
• Sensors.
• Meters/counters.

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 Implementation Road Map For Mistake Proofing

(Define)
Describe the defect or potential Apply 5 Why analysis to the
defect including the rate error conditions to determine
root causes
(Measure)
Identify where the defect is
(Improve/Control)
likely to occur
Identify (using a team approach)
(Analyze) Mistake Proofing strategies
Analyze current tasks
associated with the operation

(Control)
Identify error conditions Verify the efficiency of the
contributing to the defect Mistake Proofing actions
 The User (Producer & Customer) Is
The Best Inspector

• No one intends to make mistakes.

• While we are working, errors can show up
without us noticing.
• How can we catch these errors before they
turn into defective products?
Poka Yoke Video

https://www.youtube.com/watch?v=WnJpI
Uv48Os

On You Tube
 Ten Types of Human Mistakes
 Forgetfulness
 Misunderstanding
 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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 Contrasting Cultures
NEGATIVE APPROACH POSITIVE APPROACH
Mistakes are Inevitable Mistakes Can Be Eliminated
• people make mistakes • create the ‘right’ environment
• focus on the process deficiency
• place blame • ask “why?”, then “how?”
• detect at final inspection • learn from the opportunity
• sampling inspection • apply mistake-proofing
• errors are inevitable methods
• no time, no money • train everyone to challenge
• no support errors.
• show them it’s possible; share
examples

What is the culture in your workplace?

What is your approach?

www.freeleansite.com
The Seven Guidelines to Poka- Yoke Attainment

1.) Quality Processes - Design “Robust” quality processes to achieve zero

defects.
2.) Utilize a Team Environment- leverage the teams knowledge,experience to
enhance the improvement efforts.
3.) Elimination of Errors -Utilize a robust problem solving methodology to
drive defects towards zero.
4.) Eliminate the “Root Cause” of The Errors-Use the 5 Why’s and 2 H’s
approach
5.) Do It Right The First Time- Utilizing resources to perform functions
correctly the “first” time.
6.) Eliminate Non-Value Added Decisions- Don’t make excuses-just do it !
7.) Implement an Incremental Continual Improvement Approach-implement
improvement actions immediately and focus on incremental improvements;
efforts do not have to result in a 100% improvement immediately. 24
Elimination of Waste

The Method
Identify
waste

Check and Search for

measure causes
results

Implement
continuous
improvemen
t
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 Additional Hints for Defect Prevention
Don’t make surplus products
• make only what the customer needs, when it is needed
• surplus inventory makes poor quality harder to find
• in a high inventory environment, the sense of urgency is not there
Eliminate, simplify, or combine production operations
• identify and eliminate waste; drive 5S
• follow standard operations & utilize visual aids
Once processed, use immediately
• adopt a flow process
• implement immediate feedback and action cycles
Involve everyone in defect prevention
• form action teams - team brainstorming
Make daily improvements and invent mistake-proofing devices

A Lean environment promotes defect

prevention.
www.freeleansite.com
 Poka-Yoke
Example
 By fitting a block into the pierce tooling,
the blank plate can only go on one way.

BLOCK
There are six mistake-proofing principles or methods. These are listed
in order of preference or precedence in fundamentally addressing
mistakes:

1.Elimination seeks to eliminate the possibility of error by redesigning

the product or process so that the task or part is no longer necessary.

Example: product simplification or part consolidation that avoids a part defect or assembly
error in the first place.
2.Replacement substitutes a more reliable process to improve consistency.

Examples: use of robotics or automation that prevents a manual assembly error, automatic
dispensers or applicators to insure the correct amount of a material such as an adhesive is
applied.
3.Prevention engineers the product or process so that it is impossible to make a mistake at
all.

Examples : Limit switches to assure a part correctly placed or fixtured before process is
performed; part features that only allow assembly the correct way, unique connectors to
avoid misconnecting wire harnesses or cables, part symmetry that avoids incorrect insertion.
4.Facilitation employs techniques and combining steps to make work
easier to perform.

Examples: visual controls including color coding, marking or labeling

parts to facilitate correct assembly; exaggerated asymmetry to facilitate
correct orientation of parts; a staging tray that provides a visual control
that all parts were assembled, locating features on parts.
5.Detection involves identifying an error before further processing occurs
so that the user can quickly correct the problem.

Examples : sensors in the production process to identify when parts are

incorrectly assembled, built-in self-test (BIST) capabilities in products.
6.Mitigation seeks to minimize the effects of errors.

Examples: fuses to prevent overloading circuits resulting from shorts;

products designed with low-cost, simple rework procedures when an error
is discovered; extra design margin or redundancy in products to
compensate for the effects of errors.
Strategies for Zero Defects
1.    Don't make it !!! Don't make products that you don't need.
More products you make, then greater the opportunity for defects
as they sit in inventory. Thats why follow " Just In Time " principle
and make only what is needed, when it is needed and in the right
amount needed.
2.    Make it to withstand any use !!! The user is an expert at finding
defects. Therefore it is important to build safeguards into the
production process to ensure that product can withstand any
misuse. Quality can be built into products by thoroughly
implementing Poka Yoke, automation, and work standarization.
3.        Once you have made it, use it right away !!! If a product
spoils with time, then make sure it is used as soon as possible by
using continuous flow production.
Have a nice day and find a place for "POKA YOKE" in your
production system.

B’cause it is a simpler technique to avoid human error at work.