2. Poka -yoke is a Japanese improvement
strategy for mistake proofing to prevent
defects from arising during production
processes.
It’s aim is to achieve ‘zero defect’
3. Developed by Shigeo Shingo in 1961
Poka means mistakes yokeru means avoid
Poka-yoke refers to techniques that make it
impossible to make mistakes.
Poka-yoke techniques can drive defects out
of products and processes and substantially
improve quality and reliability.
4. Errors can be of any type-
i. Processing Error: Process operation missed or not
performed per the SOP.
ii. Setup Error: Using the wrong tooling or setting
machine adjustments incorrectly.
iii. Missing Part: Not all parts included in the assembly,
welding, or other processes.
iv. Improper part/item: Wrong part used in the process.
v. Operations Error: Carrying out an operation
incorrectly; having the incorrect version of the
specification.
vi. Measurement Error: Errors in machine adjustment,
test measurement or dimensions of a part coming in
from a supplier.
5. PREVENTION BASED
Prevents the defects from occurring
DETECTION BASED
Detects the defects and prevent its progress
6. CONTROL METHOD
This method senses a problem and stops a
line or process, so that corrective action can
take place immediately
EXAMPLE: Assembly operation in which one
component is missing before actual assembly
whole operation is stopped
7. This method signals the occurrence of a
deviation or trend of deviations through an
escalating series of buzzers, lights or other
warning devices
This method does not shut down the process
on every occurrence
8. CONTACT METHOD
This method detects any deviation in shape,
dimensional characteristics or other specific
defects, through mechanisms that are kept in
direct contact with the part
Fixed Value Method: This method is used in
operations, where a set of steps is
sequentially performed.
A sensor counts the number of times a part is
used or a process is completed and releases
the part only when the right count is reached.
9. Motion Step Method:
This method ensures that a process or
operator does not mistakenly perform a step
that is not part of the normal process.
An example of this is colour coding of
electronic components on drawings and totes
to prevent using mixed or incorrect parts.
10. Remove defect from root cause or source
Faster detection and correction
Lesser attention from workers/operators
Improve safety of workers
Improves equipment effectiveness and
assures higher reliability
11. Requires special expertise on instrumentation
knoweledge
Implementation cost is high
Training of workers is a must which adds the
cost