Poka Yoke

POKA YOKE
POKA YOKE
• In Japan POKA YOKE means “Mistake
Proofing”
• Initially it was coined as ”Fool Proofing”. Later

changed to Mistake Proofing
Poka yoke aims at:
1. Error free production
2. Defect free product (Zero Defect)

Mistake proofing
• The original “Fool Proof” was changed
to “Mistake proofing” because:
• Merely not noticing that an error is
made or a machine is not functioning
properly does not make a person stupid
or foolish.
Different kinds of Human errors
• Poka-Yoke dwells on the theme errors can be corrected.
• Errors due to forgetfulness

• Errors due to misunderstanding
• Errors in wrong identification
• Errors made by amateurs/ Lack of experience
• Wilful (ignoring rules or procedure)
• Errors due to slowness
• Errors due to lack of standards.
• Surprise errors (unexpected machine operation resulting
in panic situation)
• Intentional errors (sabotage)
The concept of Mistake proofing involves
• Control in the product or process to prevent

the occurrence of defects
• Requires simple inexpensive inspection at

the end of each successful operation to
discover and correct defects at the source
Zero Defect Quality (ZDQ)
Poka Yoke aims at Zero Defect Quality. Why is “Zero Defects” an Important
Concept?
• To Maintain Customer Satisfaction & Loyalty
• To reduce COST
The 4 Components of ZDQ
• ZDQ functions by combining four elementary components:

• 1. Point of Origin Inspection
• 2. 100 % Audit Checks
• 3. Immediate Feedback
• 4. Poka-Yoke
Inspection
The 3 basic approaches to inspection of processed

product are:
Judgement/Standard Inspection
Informative Inspection
Point of Origin Inspection
8
100% Audit Checks
Point of Origin Inspection on every piece.
The second of the 4 basic elements of ZDQ.
Differs from SQC inspection:
Does not rely on sampling
Prevents defects
Does not assume defects will statistically occur
100% Audit checks everything on the line!
9
Quick Feedback
Error correction as soon as possible
The third of the 4 basic elements of ZDQ.
Differs from traditional inspection approaches that:
Correct problems after the process
Address the problem when errors are already defects
In some cases never identify an error has occurred
ZDQ sends the operator a signal and

alarms the person that an error has
happened!
ZDQ Inspections = Immediate Feedback
10
The Seven Guidelines to Poka- Yoke Attainment
1.) Quality Processes - Design “Robust” quality processes to achieve zero

defects.
2.) Utilize a Team Environment- leverage the teams knowledge,experience to
enhance the improvement efforts.
3.) Elimination of Errors -Utilize a robust problem solving methodology to
drive defects towards zero.
4.) Eliminate the “Root Cause” of The Errors
5.) Do It Right The First Time- Utilizing resources to perform functions
correctly the “first” time.
6.) Eliminate Non-Value Added Decisions
7.) Implement an Incremental Continual Improvement Approach-implement
improvement actions immediately and focus on incremental improvements.
11
Poka-yoke Systems Govern the
Process
Two Poka-Yoke System
approaches are utilized in
manufacturing which lead to
successful ZDQ:
1. Control Approach
Shuts down the process when an
error occurs.
Keeps the “suspect” part in place
when an operation is incomplete.
2. Warning Approach
Signals the operator to stop the 12
process and correct the problem.
Control System
Takes human element out of
the equation;does not
depend on an operator or
assembler.
Has a high capability of
achieving zero defects.
Machine stops when an
irregularity is detected.
13
Warning System
Sometimes an automatic shut off system is not an option.
A warning or alarm system can be used to get an operators
attention.
Below left is an example of an alarm system using dials,
lights and sounds to bring attention to the problem.
Color coding is also an effective non automatic option.
BEEP
BEEP!
!
BEEP!
14
Methods for Using Poka-yoke
Poka-yoke systems consist of three primary methods:
1. Contact
2. Counting
3. Motion-Sequence
Each method uses a different process prevention
approach for dealing with irregularities.
15
Six Mistake Proofing Principles
1. Elimination: To eliminate the possibility of error by

redesigning the process or product
2. Replacement : Replace the process by a more

reliable one.
3. Prevention: By design the product or process is

made mistake-proof.
4. Facilitation: By using techniques that facilitate
doing the assembly jobs correctly.
5. Detection: Error detection before further

processing so that defects are identified and
corrected early in assembly.
6. Mitigation: Seeks to minimize the effects of errors

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POKA YOKE

• Initially it was coined as ”Fool Proofing”. Later

1. Error free production

2. Defect free product (Zero Defect)

• Errors due to forgetfulness

• Control in the product or process to prevent

• Requires simple inexpensive inspection at

• ZDQ functions by combining four elementary components:

The 3 basic approaches to inspection of processed

100% Audit checks everything on the line!

ZDQ sends the operator a signal and

1.) Quality Processes - Design “Robust” quality processes to achieve zero

1. Elimination: To eliminate the possibility of error by

2. Replacement : Replace the process by a more

3. Prevention: By design the product or process is

5. Detection: Error detection before further

6. Mitigation: Seeks to minimize the effects of errors

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