What is the Poka Yoke Principle and what are the Benefits? Yet using a Poka-Yoke principle is a powerful and proactive way of minimizing human error and reducing defect as a result.
Back to Categories Introduction Lean Management has adopted the principles and techniques originating as part of the Lean Manufacturing methodology and developed them even further. Now we can experience the benefits of Lean in management and transfer successful techniques from the times of post war Japan to modern day business conditions.
One of the most valuable takeaways is Poka Yoke. It has become one of the most powerful work standardization techniques and can be applied to any manufacturing or service industry. Its idea to prevent errors and defects from appearing in the first place is universally applicable and has proven to be a true efficiency booster.
Shingo also created and formalized Zero Quality Control — a combination of Poka Yoke techniques to correct possible defects and source inspection to prevent defects.
Poka Yokes ensure that the right conditions exist before a process step is executed, and thus preventing defects from occurring in the first place.
Where this is not possible, Poka Yokes perform a detective function, eliminating defects in the process as early as possible. Poka Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
Examples of Poka Yoke Application In a broader sense, it is also a behavior-shaping constraint as a process step to prevent incorrect operation.
One of the most common is when a driver of a car with manual gearbox must press on the clutch pedal a process step — Poka Yoke before starting the engine. The interlock prevents from an unintended movement of the car.
These serve as behavior-shaping constraints as there are actions that must be performed before the car is allowed to start.
Other examples can be found in the child-proof electric sockets or the washing machine that does not start if the door is not closed properly in order to prevent flooding. Why is Poka Yoke important? The value of using Poka Yokes is that they help people and processes work right the first time, which makes mistakes impossible to happen.
These techniques can significantly improve quality and reliability of products and processes by eliminating defects. This approach to production fits perfectly the culture of continuous improvementwhich is also part of the Lean management arsenal.
Applying simple Poka Yoke ideas and methods in product and process design can eliminate both human and mechanical errors. The flexibility of Poka Yoke allows for it not to be costly. Depending on the size of the company, it can be an extremely cost-efficient endeavor. When and how to use it?
Poka Yoke technique could be used whenever a mistake could occur or something could be done wrong — meaning everywhere. It can be successfully applied to any type of process in manufacturing or services industry, preventing all kinds of errors: Process operation missed or not performed per the standard operating procedure.
Using the wrong tooling or setting machine adjustments incorrectly. Not all parts included in the assembly, welding, or other processes.
Wrong part used in the process. Carrying out an operation incorrectly; having the incorrect version of the specification. Errors in machine adjustment, test measurement or dimensions of a part coming in from a supplier.
Poka yoke is easy to implement because of its universal and rational nature. You can follow this step by step process to apply it: Identify the operation or process. Analyze the 5-whys and the ways a process can fail. Choose the right Poka Yoke approach, such as using a shutout type preventing an error being madeor an attention type highlighting that an error has been made.
Take a comprehensive approach instead of thinking of Poka Yokes just as limit switches, or automatic shutoff. Determine whether a contact use of shape, size or other physical attributes for detectionconstant number error triggered if a certain number of actions are not madeor a sequencing method use of a checklist to ensure completing all process steps is most appropriate.
Test the method and see if it works. Train the operator, review performance and measure success.inspect % of the items, provide immediate feedback to compel countermeasures, source inspections are the most powerful poka-yoke, informative inspections can be effective, especially when based on self-or successive checking.
Introduction to Poka Yoke. Poka Yoke is a quality assurance technology developed by the Japanese Manufacturing engineer Shigeo Shingo.. The Goal of Poka Yoke is to eliminate product defects by preventing or correcting errors as early as possible.
Poka Yoke is . Methods in Detail21 Motion-Sequence Method: The third poka yoke method uses sensors 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 sensor signals a timer or other device to stop the machine and signal the operator.
The Poka Yoke principle has also found favor in IT where agile development is practiced – a method called “test-driven design” (or TDD).
This requires the test to be written before any code is developed. In the manufacturing industry, there are two types of Poka Yoke: Control Poka Yoke and Warning Poka Yoke. Control Poka Yoke is more ideal. By changing process steps or tweaking your tools, Control Poka Yoke is to make it mechanically impossible for a mistake to happen in your process.
Poka Yoke Definition & Meaning “Poka-Yoke” a Japanese term coined by Shiego Shingo in the ’s meaning “mistake-proofing”. It is a highly effective quality control tool.