Poka Yoke

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  Poka-yoke (ポカヨケ) is a Japanese term that means "mistake-proofing".  It is derived from poka o yokeru (ポカを除ける), a term in shogi and igo referring to avoiding an unthinkably bad move.  

Poka Yoke is a series of techniques used to error proof, mistake proof or create a fail-safe process that is designed to prevent errors, defects or mistakes.  Even more specifically a poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to errors as they occur. 

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How does Poka Yoke Work?
Poka Yoke devices essentially help facilitate two very critical aspects in preventing errors:

1. They help accomplish 100% inspection.
2. They provide quick and almost immediate feedback when errors do occur that helps an operator take corrective action before the error turns into a defect.

  In the simplest form a poka yoke will either shut down a process, machine or line when an error occurs or signal the operator. The most effective poka yokes are achieved with source inspection. However, poka yokes can also be effective with informative inspection methods.  Keep in mind that the informative type poka yoke checks only after the defect or error has occurred with either the successive check or self check methods.  While this is effective in stopping the defects from traveling, it is not as effective as a poka yoke at the source.
  The concept of Poka Yoke was formalized, and the term adopted, by Shigeo Shingo as part of the Toyota Production System.​  Dr. Shingo outlined the Poka Yoke techniques in the book Zero Quality control: Source Inspection and the Poka Yoke System.
Tip:
  Much of the Poka Yoke System requires quality focused behaviors.  Those involved or attempting to achieve Zero Quality Control Should support three basic principles of defects:

1. Don’t accept a D​efect.
2. Don't Make a Defect.
3. Don't Pass on a Defect.

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Other Resources:

• Video - Introduction to Poka Yoke Systems in JIT.
• Video - ZQC and Poka Yoke Intro in JIT. 

​Challenge:

• ​Is there an error that you see everyday?  What ways could you prevent that error from occurring?  Share your thoughts in the comments section below and receive a coupon to one of Lean Strategies International LLC's courses.

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