What is Poka Yoke? (Definition, Examples, and Benefits)

12/10/2022 12:00 AM by Small SEO Tools in Info

poka yoke

Poka Yoke is about helping anyone avoid mistakes that happen in any process. The poka-yoke can be applied at any stage of the manufacturing process where something may go wrong or an error may occur. So friends in this post What is poka yoke? Learn about poka yoke, types of poka yoke, definition of poka yoke, poka yoke meaning etc.

What is poka yoke?

Poka-yoke It is a device or mechanism system, the purpose of which is to eliminate defects in products by preventing or correcting defects and drawing the attention of employees to errors. Poka Yoke It is a Japanese word, in which Poka means Mistake and Yoke means Proofing.

It was originally described as Baka-Yoke, which means Fool-Proofing or Idiot-Proofing. But this name was changed to Poka-yoke which means Mistake Proofing or Error Proofing.

Definition of poka-yoke

Poka Yoke is a method in Lean Manufacturing process, which helps in avoiding mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors.

Poka Yoke meaning

Poka Yoke means Mistake Proofing or Error Proofing, which means error prevention or defect proofing.

Purpose of Poka Yoke and Poka Yoke Concept

The poka-yoke concept was applied in the 1960s by "Shigeo Shingo" of Japan to industrial processes designed to prevent human errors.

Poka-Yoke aims to design a process so that faults can be quickly detected and corrected while eliminating defects at source.

Poka Yoke can be applied at any stage of the manufacturing process where something may go wrong or a defect/error may occur.

Poka Yoke Implementation in Manufacturing

This process can be implemented at any stage of the manufacturing process, where some defect may occur or something may go wrong or an error may occur.

Shigeo Shingo recognized three types of poka-yoke to detect and prevent defects or errors in a mass production system, that is, product's shape, product's size, color, or other physical attributes. These methods identify the defects and error of the product by testing the products.

Shingo states that, errors are inevitable in any manufacturing process, but if proper Poka Yoke is implemented, mistakes can be caught quickly and prevented from resulting in defects. By eliminating defects at the source, the cost of mistakes within a company is reduced. And the quality of manufacturing or production can be improved.

For example, the poka-yoke device actually prevents mistakes from happening. In manufacturing, the operator is alerted when a fault is about to occur, so that it can be stopped before it occurs.

Three Stage Management

A systematic approach to creating a poka-yoke counter-measure is suggested through the Applied Problem Solving (APS) methodology, which involves a three-stage approach to managing risks.

  • Identification of the need
  • Identification of possible mistakes
  • Management of mistakes before satisfying the need

Types of Poka Yoke

There are two types of poka-yoke, one is Prevention Poka Yoke and the other is Detection Poka Yoke. Both these methods are used in the manufacturing process. Let's know about them:

Prevention Poka Yoke:

Prevention Poka Yoke prevents error or defect from occurring in any process.

Detection Poka Yoke:

It allows a defect or error to occur in production, but it detects the defect or error as early as possible in the same process or further process steps, and removes that defect or error.

Benefits of poka-yoke implementation

The biggest advantage of poke-yoke is the elimination of defects in products by preventing or correcting defects and drawing attention to employee errors. And other benefits are also included with it.

  1. 100% quality control.
  2. Immediate action when there is a problem.
  3. Adoption of process related to quality control.
  4. Spend a minimum of time on training.
  5. Detection of faults before they occur.
  6. Preventing defective products from reaching the customers.
  7. Improving the quality of all products.
  8. Least number of rejections.
  9. Customer solution or customer satisfaction towards the product.
  10. The cost of mistakes within the company is reduced.
  11. Management of mistakes before the requirement is met.