Mistake Proofing

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Contents
 INTRODUCTION & BACK GROUND

 NEED

 WHEN IT IS USE

 HOW TO USE IT

 TYPES OF POKA-YOKE

 METHOD OF POKA-YOKE

 EXAMPLES

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1. INTRODUCTION & BACKGROUND

Introduction-
 Pronunciation - POH-KAH-YOH-KAY
Poka-Yoke is a Japanese word that means Mistake Proofing.
Poka-Yoke is a combination of two word -
POKA – Mistake
YOKE – to avoid (Proofing)

xyrh ls Hkh xyrh u gksA

- Poka-Yoke is a concept which is related to restricting Errors at source itself which
adversely affect -

- Our Customers & Consumers (Defects)

- Our employees (injuries)

- A Poka-Yoke refers to techniques that make it impossible to make mistakes.

Poka-Yoke means to make the mistake proof process

-- The aim of Poka-Yoke is to design the process so that mistakes can be detected and
corrected immediately, eliminating defects at the source.
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1. INTRODUCTION & BACKGROUND
EXAMPLES-
Figure 1 shows the concept of the Poka-Yoke system.
1. In upper diagram, size of both holes are same,
therefore there may be mistake of putting positive
terminal into negative hole
2. but on the other hand, in lower figure, the sizes of
both the holes are different which results in avoiding
the misplacement of the terminal into wrong hole.

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1. INTRODUCTION & BACKGROUND

Background

Shigeo Shingo invented the Japanese

Concept called “POKA-YOKE”

The name Poka-Yoke was established by Shigeo Shingo in 1960, it is

translated as “Resistance to errors"
The initial term was ‘Baka-Yoke’, which means ‘fool-proofing’. This term
‘baka-yoke’ was dishonorable & offensive. Hence, the term was changed to
poka-yoke, which means ‘mistake proofing’.

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2. NEED

Organization sells the quality products to the customer.

The success of any organization depends on the quality of product especially
right product produced.

In order to make more profit, either increase the selling price or decrease
the cost.
When any organization decides to implement the lean manufacturing then
one of the objective is to reduce waste.

Wastes = How many types?

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2. NEED

What is Error?
Error/Mistake – deviation from what is correct, right or true.
How to Prevent Error-

 Old Way Scold worker

Re train worker
Motivational Talks

 New Way/
Remove the opportunity for error
Better Way • Improve the process
• Make wrong actions more difficult
If you can’t remove the opportunity for error
• Make it easier to discover the error do occur

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2. NEED

What causes defects?

 Errors Lead to Defects-
The cause of defects lie in worker errors, and defects are the result
of those errors.

1. Poor Procedures or Standards

2. Machines
3. Non-conforming material
4. Worn Tooling
5. Human Error/mistakes

Except for human mistakes these conditions can be predicted and corrective action can be
implemented to eliminate the cause of defects

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2. NEED

Human Mistakes- Simple errors-the most common cause of defects-occur unpredictably.

 Ten Types of Human Errors –

1. Forgetfulness
2. Misunderstanding
3. Wrong Identification
4. Lack of experience
5. Willful (Ignorance of procedure or rules)
6. Slowliness
7. Lack of Standardization
8. Surprise (Unexpected Machine Operation etc.)
9. Intentional
10. Inadvertent or sloppiness

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3. WHEN TO USE IT

 It is a technique, a tool that can be applied to any type of process be it in manufacturing

or the service industry.
 Poka-yoke can be used wherever something can go wrong or an error can be made

 Errors can be of any type-

1. Processing Error: Process operation missed or not performed per the SOP.
2. Setup Error: Using the wrong tooling or setting machine adjustments incorrectly.
3. Missing Part: Not all parts included in the assembly, welding, or other processes.
4. Improper part/item: Wrong part used in the process.
5. Operations Error: Carrying out an operation incorrectly; having the incorrect version of
the specification.
6. Measurement Error: Errors in machine adjustment, test measurement or dimensions of
a part coming in from a supplier.

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4. HOW TO USE IT

Step by Step Process in applying Poka-Yoke-

1. Identify Problem

2. Observation at work stations

3. Brain Storming for idea

4. Select best ideas

5. Implementation plan & Implementation

6. Monitoring & signoff

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5. TYPES OF POKA-YOKE

Poka-yoke Devices Fall into two categories

Prevention Detection
(control) (Warning)

A) Prevention (Control) – A Prevention device engineers the process so that it is impossible

to make a mistake at all.
• Shuts down the process when an error occurs.
• High capability of achieving zero defects.
B) Detection (Warning) – A Detection device signals the operator when a mistake has been
made, so that the user can quickly correct the problem.
• Signals the operator to stop the process and correct problem or check for a problem.
• Dials, lights, and sounds to bring attention to the problem.
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6. MISTAKE PROOFING DEVICES

Motion
Contact
Sequence

Counting

Each method can be used in a control system or a warning system.

Each method uses a different process prevention approach for dealing with irregularities.

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 6. MISTAKE PROOFING DEVICES

1. Contact Method
A contact method functions by detecting whether a sensing device
makes contact with a part or object within the process.
Cylinder present Missing cylinder; piston fully
An example of a physical contact method is extended alarm sounds

limit switches that are pressed when cylinders

are driven into a piston. The switches are
connected to pistons that hold the part in
place.
In this example, a cylinder is missing
Cannot proceed to
and the part is not released to the next next step.
process.
Contact Method using limit
Do not have to be high tech! switches identifies missing cylinder.

Passive devices are sometimes the best method. These can be as simple as guide pins or blocks that do not
allow parts to be seated in the wrong position prior to processing

Take advantage of parts designed with an uneven shape!

This method signals to the operator right away that the part is not in proper position.

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6. MISTAKE PROOFING DEVICES

Physical Contact Devices

Toggle Switches
Limit Switches

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6. MISTAKE PROOFING DEVICES

Energy Contact Devices

Photoelectric switches can
Light
be used with objects that
are translucent or
transparent depending upon
the need.
Transmission method: two units,
Transmitter Receiver one to transmit light, the other
to receive.
Reflecting method: PE sensor
responds to light reflected from
object to detect presence.
Object

If object breaks the transmission, the machine is signaled to shut

down.
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6. MISTAKE PROOFING DEVICES

2. Counting Method
Used when a fixed number of operations are required within a process, or when a
product has a fixed number of parts that are attached to it.
A sensor counts the number of times a part is used or a process is completed and
releases the part only when the right count is reached.

In the example to the right a limit switch is used to

detect and count when the required amount of holes
are drilled. The buzzer sounds alerting the operator
that the appropriate amount of steps have been taken
in the process.

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6. MISTAKE PROOFING DEVICES

3. Motion-Sequence Method
The third poka-yoke method uses sensors & Photo electric devices with timer to
determine if a motion or a step in a process has occurred. If the step has not occurred
or has occurred out of sequence, the the sensor signals a timer or other device to stop
the machine and signal the operator.

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6. MISTAKE PROOFING DEVICES

Motion-Sequence Method
In order to help operators select the right parts for the right step in a process
the “sequencing” aspect of the motion-step method is used. This is
especially helpful when using multiple parts that are similar in size and
shape.
In this example, each step of the machine cycle is wired to an indicator board
and a timer. If each cycle of the machine is not performed within the required
“time” and “sequence”, the indicator light for that step will be turned on and the
machine will stop.

Machine Indicator Board

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 7. EXAMPLES
•Magnets in a grain packaging plant detect and remove metal pieces before they are
packed.

•Interlock switches which detect the position of a machine guard and switch off the
machine when the guard is lifted. The machine will never operate when the guard has been
lifted and this prevents accidents to the operator.

•Safety mats near machine areas that pose a danger automatically trigger stoppage when
someone steps on them. This prevents injury to personnel (such are technicians) who are
trying to access dangerous sections of a machine.

•Power guards on high inertia machines with moving parts prevent opening until the parts
have stopped completely in order to prevent accidents.

•Machines that must be controlled using both hands ensure that some distance is kept
between the operator and dangerous machine parts.

•Using standardized containers at the workstation enables workers to know exact

quantities without having to weigh or count the contents.

•Use of colour coded date labels to mark the production dates of products. This way the
different batches are easily identifiable for the purpose of product rotation. The system is
especially useful in the food industry where rotation of batches is very important because of
hygiene considerations.
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7. EXAMPLES

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To prevent mistakes, develop error proofing
devices
POKA-YOKE
to avoid (yokeru) inadvertent errors (poka)

 Checklists
 Locating pins
 Error & alarm detectors
 Limit or touch switches
 Detectors, readers, meters, counters

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 3 Rules of POKA-YOKE
 Don’t wait for the perfect POKA-
YOKE. Do it now!
 If your POKA-YOKE idea has better than
50% chance to succeed…Do it!
 Do it now….improve later!

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THANK YOU

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