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Poka-yoke (ポカヨケ) is a Japanese term that means “fail-safing” or “mistake-proofing”. A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota Production System or Lean Manufacturing. It was originally described as baka-yoke, but as this means “fool-proofing” (or “idiot-proofing”) the name was changed to the milder poka-yoke.
The articles below show examples of Poka-Yoke, the problem the actual Poka-Yoke device is meant to solve, and how you might apply the principle of Mistake Proofing to your work.
1) What is Poka-Yoke?
2) When to use Poka-Yoke?
3) How to use Poka-Yoke?
Share on Twitter Share on Google+ Share on Facebook Share on LinkedIn There are several approaches to checking for errors. In this article, I’ll discuss three common ways to check for process errors: Successive Check, Self Check, and Poka-Yoke (mistake proof). Below is a table that describes the three common strategies for checking errors and [...]
Share on Twitter Share on Google+ Share on Facebook Share on LinkedIn We know that when there is no standard, there is no Kaizen. We often think of this statement as referring to just processes. But, standards apply to a broad range of categories – even to the language, the means by which we communicate. [...]
Share on Twitter Share on Google+ Share on Facebook Share on LinkedIn Poka-Yoke, or Error-Proofing or Mistake-Proofing, is an essential aspect of process improvement. In fact, Poka-Yoke is the method by which we can actually get closer to a goal of zero defects without an exponential increase in the cost to detect and eliminate defects. [...]
Share on Twitter Share on Google+ Share on Facebook Share on LinkedIn A few weeks ago, I visited a Distribution Center in Nevada. On our Gemba Walk thorugh the Warehouse, I noticed some very interesting applications of Visual Management. One interesting aspect of Lean that I saw was an application of Poka-Yoke to prevent Order [...]
Share on Twitter Share on Google+ Share on Facebook Share on LinkedIn My wife found this ad in a local newspaper that was both amusing and dangerous. But, it presented a great opportunity to implement Poka-Yoke. Here’s the text of the Ad: Garland, UT 84312 – Nov 12, 2010 Evenflo Stroller – has 1 issue [...]
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