What is Poka-yoke?

Poka-yoke Examples

How to implement Poka-Yoke in manufacturing?

Steps of Poka-yoke Implementation:

Identification Problems Prioritize Seek root cause Find and Implement solutions Measure the results

What are the types of poka-yoke?

Contact Method Constant Number (or fixed-value) method Sequence (or motion step) method

The contact method:

The constant number (or fixed-value) method:

The sequence (or motion step) method:

Poka-Yoke Principles

Quality Processes Utilize a Team Environment Elimination of Errors Eliminate the Root Cause Do It Right The First Time Eliminate Non-Value Added Decisions and Activity Implement a Continual Improvement Approach

Six Poka-Yoke Techniques Explained with Examples

Elimination Replacement Prevention Facilitation Detection Mitigation

Elimination:

Replacement:

Prevention:

Facilitation:

Detection:

Mitigation:

Benefits of poka-yoke implementation:

→ Poka-yoke means "error proofing" or "mistake-proofing". It came from the word "Poka" which means "mistake" and "Yokeru" which means "to avoid" and it is a Japanese term.→ It is any mechanism in any process that helps for "mistake-proofing" or "error proofing".→ We can eliminate product defects by preventing it, correcting it, or detecting is as they occur.→ It is one of the→ This concept was adopted, by Shigeo Shingo as part of the Toyota Production System.→ Shigeo Shingo used the word "Poka_yoke" in the 1960s for the prevention of human error during industrial processes design.→ A simple example is when we start a car having a manual gearbox, we must have to press on the clutch pedal before starting.→ This prevents us against the unintended movement or jerk of the car during the starting→ Seat Belt wearing Indicator.→ Auto-locking of the door at the certain speed of the car.→ Bar code for correct product identification→ It can be implemented at any step of the manufacturing process.→ We should implement this tool, where the possibility of something can go wrong or an error can be made.→ It is a part of→ Shigeo Shingo recognized three types for detecting and preventing errors in a process as mentioned below.→ The contact_method identifies defects using a part’s shape, color, size, other physical attributes.→ It can also include limit switches and proximity sensors.→ When certain movements are not made then this error-proofing or mistake-proofing tool informs the operator this_method is known as the constant number (or fixed-value) method.→ Counters can be used for this at each step of the process as necessary.→ This method ensures the sequence fo the process step before moving to the next step.→ This is known as the sequence (or motion step) method.→ The sequence_method is not allowing the mistake to be made in the first place.→ Example of sequence_method is color coding and tagging and this parameter are checked at each step before moving forward.[1] Quality Processes:→ Make a robust process design for zero defect manufacturing.[2] Utilize a Team Environment:→ For any improvement, brainstorm with the teams so we can use their knowledge and experience to implement our improvement.[3] Elimination of Errors:→ Use various problem-solving methodologies or techniques for reducing defects and decrease defect to zero.[4] Eliminate the Root Cause:→ Eliminate the root cause of any problem by implementing this tool.[5] Do It Right The First Time:→ Make the process very effective to perform functions correctly for the first time.[6] Eliminate Non-Value Added Decisions and Activity:→ Identify all non-value added decisions and activities and eliminate them.[7] Implement a Continual Improvement Approach:→ We can not get 100% result in a single try.→ So, implement improvement actions immediately and focus on continual improvements so we can get a 100% result.→ Primarily focus on elimination→ In Elimination, we have to eliminate the step that is responsible for the mistake→ Remove Non-Value Added activities→ Redesign the product and modification of the process (as applicable)→ Examples: Replace manual data entry with barcode scanning→ If elimination is not possible the second option is Replacement.→ In Replacement, we have to replace the step with a more reliable mistake-proof one→ Automation of repetitive motion activities→ Examples: Welding Robotics for an automotive manufacturer→ If the above two methods are not possible then the 3rd option is prevention.→ Change product or process (as applicable) so that mistake is prevented.→ Prevention is a physical barrier to prevent undesired action.→ Examples: Safety guards on rides, Plugs for 110V & 220V, Printer cartridges and Go/No Go Gauges, etc...→ If the above three methods are not possible then the 4th option is facilitation.→ Facilitation is to help someone to take the right decision.→ We can facilitate any process or product by visual controls like color coding, labels, lines, and signs, etc...→ Examples: Warning signs, Checklists, Traffic lane markings, Color-coded parts or tools, etc...→ If the above four methods are not possible then the 5th option is facilitation.→ Detection is to identify or detect the wrong product or process immediately after it happens→ We can provide detection by Sensors, limit switches, or light sensors→ Examples: Safety guard limit switches to prevent machine running in an open condition, Computer warning if all information is not filled in→ If the above five methods are not possible then the 6th option is mitigation.→ Mitigation is to minimize the effects of mistakes or failures.→ This method is used when the mistake cannot be eliminated→ Examples: Personal protective equipment, Airbags in cars, Electrical Fuses, and An eraser on a pencil, etc...→ Elimination of many operations related to quality control → Increase the motivation of an employee→ Reduce the overburden of operators from repetitive operations→ A reduced number of rejects→ Immediate action when a problem occurs→ 100% built-in quality control.→ Less time spent on training workers→ Promotion of the work improvement-oriented approach