1. Poka-Yoke
Presented By-: Kamal Prasad Bhusal
PGPM(2011-2013)
Unitedworld School of Business

2. What is Poka-Yoke ?
 Invented by Shigeo Shingo who was
industrial engineer in Toyota
 This is known as Mistake proofing
 Mistake proofing and Poka-Yoke is the use
of process or design features to prevent
errors or their negative impact
 From Japanese:
 Poka - inadvertent errors
 Yokeru- to avoid

3. What does Poka-Yoke do ?
 Eliminates the cause of an error at the
source
 Detects an error as it is being made
 Detects an error soon after it has been
made but before it reaches the next
operation

4. POKA-YOKE
MEANS
ZERO DEFECTS

5. Two strategies for Zero defects
1. Don’t make it

6. 1. Don’t make it
 Don’t make product you don’t need
 The more you make, the greater the
opportunity for defects
 Follow ‘just-in-time’ principles by only
making what is needed, when it is
needed in the amount needed

7. 2. Build safeguards

8. 2. Build safeguards
 The user is an expert in finding defects
 Therefore build safeguards into the
production process
 Quality can be built into products by
implementation of Poka-Yoke

9. Poka-Yoke Devices
-Error Detection and Alarms

10. Poka-Yoke
- Checklists

11. Poka-Yoke Example
 It is possible to mount the blank the
wrong way onto the pierce tool
Blank Pierced Blank Incorrect
 As the blank can fit the pierce tool in
many ways, how can this be prevented?

12. Poka-Yoke Example contd….
 By fitting a block into the pierce tooling, the
blank plate can only go on one way
Block

13. Thank You