What is poka yoke?, Classification of poke yoke Poka, What Causes Defects?, Why is it important?, When to use it?, Step by step process in applying poka-yoke, Characteristics of Poka Yoke devices, ADVANTAGES and LIMITATIONS.
2. What is poka yoke ?
Poka yoke is mistake
Changed to POKA-
mistake-proofing. Shigeo Shingo
Poka-yoke is a quality assurance technique ,the aim of poka-
yoke is to eliminate defects in a product by preventing or
correcting mistakes as early as possible.
Classification of poke yoke Poka
Yoke as Prevention Device:
Poka Yoke as Detection Device:
7. Why is it important?
Helps people and processes.
Refers to techniques that make it impossible to make
Use the ideas and methods in product and process
design which can eliminate both human and mechanical
8. When to use it?
It is a technique, a tool that can be applied to any type of
process be it in manufacturing or the service industry.
Poka-yoke can be used wherever something can go
wrong or an error can be made.
Errors can be of any type-
Processing Error: Process operation missed or not
performed per the SOP.
Setup Error: Using the wrong tooling or
setting machine adjustments incorrectly.
Missing Part: Not all parts included in the assembly,
welding, or other processes.
Improper part/item: Wrong part used in the process.
Operations Error: Carrying out an operation incorrectly;
having the incorrect version of the specification.
Measurement Error: Errors in machine adjustment, test
measurement or dimensions of a part coming in from a
10. Step by step process in applying
Identify the operation or process
Decide the right Poka-yoke approach, such as
Shut out Type: Preventing an error being made.
Attention Type: Highlighting that an error has been made.
11. Characteristics of Poka Yoke
Simple and cheap
Part of the process, permitting 100% inspection
Placed close to where the mistakes occur, providing quick
Designed to stop a particular mistake
A detection device cannot provide a complete error proof
Remove defect from root cause or source
Faster defect detection and correction
Less attention from worker/operators
Improve safety of workers
Improve equipment effectiveness and assures higher
Requires special expertise in terms of instrumentation
Requires work culture of 100% inspection and
perfectionism, which is difficult to sustain
Worker may sometimes fiddle with the instruments,
especially settings on their machines, resulting in losses to