Poka-Yoke, or Error Proofing, Mistake Proofing is a helpful tool in Lean Thinking. Â But, like any tool, there’s a method to how to implement the principle of “prevent defects from happing”. Â And, the method and principle is important to know, otherwise the situation becomes one of learning how to use a hammer and then looking at everything as a nail.
|Other Poka-Yoke Examples and Articles|
What Are We Solving For?
Here’s one example:
- Defect:Â MyÂ child opens doors he is not supposed to open, endangering his safety.
- Root Cause:Â Nothing prevents my child from opening the door
- Countermeasure:Â Prevent the Door from Opening
The problem solving involved in implementing the principle of Poka-Yoke still follows the Plan-Do-Check-Act (adjust) cycle, as I show above. Â The countermeasure?
Yeah, prevent the door knob from being opened. Â This simple Poka-Yoke device will prevent your children from opening doors and potential safety hazards. Â Simple, right? Â But, the important lesson is the thinking that went into the development of this device – a device that became a huge market for this company (Safety First, Safety 1st).