Poka-yoke (ポカヨケ, [poka joke]) is a Japanese term that means "mistake-proofing" or "inadvertent error prevention". A poka-yoke is any mechanism in a process that helps an equipment operator avoid (yokeru) mistakes (poka) and defects by preventing, correcting, or drawing attention to human errors as they occur.
The Toyota Production System is focused completely around maximum efficiency and fault-free processes. That’s the idea behind Poka-Yoke.
Poka-Yoke (English: mistake-proofing): Fail safe devices in the production process that automatically stop the line in case of an error.
A Poka-Yoke is any part of a manufacturing process that helps a Toyota member avoid (yokeru) mistakes (poka).
Its purpose is to eliminate defects by preventing, correcting, or highlighting errors as they occur – for example, a jig that holds parts for processing might be modified to only allow them to be held in the correct arrangement. In a wider sense, the term can refer to any behaviour-shaping constraint designed into a process to prevent incorrect operation by the user.
Mistake-proofing is a part of the continuous improveme
For Zero defects, Shigeo Shingo came up with an industrial engineering solution. Industrial engineering needs efficiency sense and focus. They have to use engineering knowledge to improve the efficiency of engineering systems and reduce costs. The solution proposed by Shingo for zero defect production is Poka-Yoke. The features built into the machine and associated devices that prevent defects from happening. The features inform the operator that a mistake has happened and provide him an opportunity to correct the mistake.
Familiar examples of Poka Yoke
1) Warning about missing attachment file you get while composing email using Gmail.
2) Websites showing password strength indicator to show password strength. So weak passwords are avoided.
3) Google search engine feature to auto-suggest spelling corrections for user search query. This helps uses to avoid making inadvertent mistakes during search.
Poka-Yoke Presentation for ASQ - Spada UNS - PPT
23-Oct-2021
Poka-Yoke - Books - Bibliography
‘POKA YOKE’ OR QUALITY BY MISTAKE PROOFING DESIGN AND CONSTRUCTION SYSTEMS
Iris D. TommeleinDirector, Project Production Systems Laboratory, http://p2sl.berkeley.edu/, and Professor,
Engineering and Project Management Program, Civil and Environmental Engineering Department,
215-A McLaughlin Hall, University of California, Berkeley, CA 94720-1712,
http://p2sl.berkeley.edu/wp-content/uploads/2016/04/Tommelein-2008-Poka-Yoke-or-Quality-by-Mistake-Proofing-Design-and-Construction-Systems.pdf
2008 Paper on Shingo System
http://www.cba.uri.edu/research/workingpapers/documents/2008/animplementationoftheshingosystem.pdf
Mistake-Proofing for Operators: The ZQC System
Shigeo Shingo, Productivity Press Development TeamProductivity Press, 01-Jan-1997 - Business & Economics - 80 pages
The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. This book introduces operators and assembly workers to the basic methodology of ZQC in an easy-to-read format that covers all aspects of this important manufacturing improvement strategy.
Mistake-Proofing for Operators includes the instructional features that are the signature of the Shopfloor Series. In this series Productivity Press has taken the lead in adult education by teaming with instructional designers to develop complete programs for frontline learning. The goal: to place powerful and proven improvement tools such as ZQC and mistake-proofing in the hands of your company's entire workforce.
Winner of the 1990 Shingo Prize for Excellence in Manufacturing, Mistake-Proofing for Operators is based on Zero Quality Control: Source Inspection and the Poka-Yoke System by Shigeo Shingo
http://books.google.co.in/books?id=KVQCKuhdWxgC
Download and Read the very interesting first chapter. Very good explanation by Shigeo Shingo on Production Systems and Inspection.
Poka-Yoke: Improving Product Quality by Preventing Defects
Nikkan Kogyo Shimbun, Factory MagazineProductivity Press, 1988 - Business & Economics - 282 pages
If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole.
The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants.
The book:
Organizes examples according to the broad issue or problem they address.
Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes.
Provides sample improvement forms for you to sketch out your own ideas.
Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)
http://books.google.co.in/books?id=hR_8Ulz6d_oC
Poka-Yoke - Case Studies - Examples
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https://www.youtube.com/watch?v=3eUbN_5tuwM
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Poka Yoke in PCB Manufacturing: Key Advantages and Disadvantages
Poka Yoke in Information Systems and Processes
Poka Yoke concept can also be applied for information worker productivity improvement leveraging new digital technologies (Intelligent Poka yoke where technology meets tradition).
October 2021
Improve Productivity with Poka Yoke Inspection.
RNA Carpet Gap Hider Poka Yoke Station – RNA have designed and built a bespoke workstation, applying Poka-Yoke (also called mistake proofing) requirements to prevent the human errors that result in product defects.
Poka Yoke in PCB Manufacturing: Key Advantages and Disadvantages
https://www.tempoautomation.com/blog/poka-yoke-in-pcb-manufacturing-key-advantages-and-disadvantages/
Mistake Proofing, Poka-Yoke Style.
- 11/05/2018
mobile cart with poka-yoke
Five parts are to be picked on put on the cart. The design makes sure the associate puts the correct part on the car. This cart is wireless and speaks directly if the incorrect part is picked, or if the part is missed completely and the cart is moved.
Mistake Proofing, Poka-Yoke Style.
- 11/05/2018
mobile cart with poka-yoke
Five parts are to be picked on put on the cart. The design makes sure the associate puts the correct part on the car. This cart is wireless and speaks directly if the incorrect part is picked, or if the part is missed completely and the cart is moved.
Lean Manufacturing in Real Life: 10 Examples of Poka-Yoke in Daily Life
Angie Lin Boyer
Jul 17, 2021
POKA YOKE IMPLIMENTATION ON PUNCHING MACHINE
Application Poka-Yoke to Capture Defect
This paper focuses on process improvement in a horn manufacturing company, using mistake proofing technique or Poka -Yoke.
https://acadpubl.eu/hub/2018-119-17/2/180.pdf
19-Dec-2017 — Based on case study results, this paper presents a theoretical framework to unify developments in the design for Poka-Yoke.
https://www.researchgate.net/publication/274289910_Quality_improvement_through_Poka-Yoke_From_engineering_design_to_information_system_design
30 June 2015. IMPLEMENTATION OF POKA-YOKE. TECHNIQUE IN A GEAR INDUSTRY – A CASE. STUDY.
https://www.mnkjournals.com/journal/ijlrst/pdf/Volume_4_3_2015/10522.pdf
Passenger Car Seat Quality Improvement Through Poka-Yoke
http://www.irdindia.in/journal_ijmer/pdf/vol1_iss2/16.pdf
Implementation of Poka-Yoke System in an Automotive.
by BD de Souza Silva — This article aims to present the Poka-Yoke error-proof system, ... benefits to a company by means of its implementation in a case study.
http://ijrsset.org/pdfs/v5-i3/5.pdf
Implementation of Poka Yoke in Needle Bearing Assembly
http://www.ijesi.org/papers/Vol(6)11/Version-3/A0611030110.pdf
Use of Poka-Yoke to Prevent Losses in a Metallurgical Plant
http://www.ijeert.org/papers/v4-i7/4.pdf
https://leanfactories.com/poka-yoke-examples-error-proofing-in-manufacturing-daily-life/
https://www.rnaautomation.com/blog/poka-yoke-in-manufacturing/
https://tulip.co/blog/lean-manufacturing/poka-yoke-examples-everyday-life/
Training Programs
IndiaShingo Institute of Japanese Management, Bangalore and Hyderabad
http://www.shingoinstitute.ac.in/poka-yoke.php
UK
http://www.poka-yoke.org.uk/
Updated 23 November 2021, 18 August 2019, 21 August 2017, 25 February 2017, 21 December 2013
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