What is Poka-Yoke?
Examples of Poka Yoke Application
Other examples can be found in the child-proof electric sockets or the washing machine that does not start if the door is not closed properly in order to prevent flooding. These types of automation don’t allow mistakes or incorrect operation from the start.
Why is Poka Yoke important?
The value of using Poka Yokes is that they help people and processes work right the first time, which makes mistakes impossible to happen. These techniques can significantly improve quality and reliability of products and processes by eliminating defects. This approach to production fits perfectly the culture of continuous improvement, which is also part of the Lean management arsenal.
When and how to use it?
Poka Yoke technique could be used whenever a mistake could occur or something could be done wrong – meaning everywhere. It can be successfully applied to any type of process in manufacturing or services industry, preventing all kinds of errors:
• Processing error: Process operation missed or not performed per the standard operating procedure.
• 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.
•Measurement error: Errors in machine adjustment, test measurement or dimensions of
Poka yoke (pronounced “poh-kah yoh-kay”) comes from two Japanese words – “yokeru” which means “to avoid”, and “poka” which means “inadvertent errors.” The main objective of poke yoke is to achieve zero defects.
Poka Yoke means ‘mistake-proofing’ or more literally – avoiding (yokeru) inadvertent errors (poka).
Poka Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes.
Examples of Poka Yoke Application
Other examples can be found in the child-proof electric sockets or the washing machine that does not start if the door is not closed properly in order to prevent flooding. These types of automation don’t allow mistakes or incorrect operation from the start.
Why is Poka Yoke important?
The value of using Poka Yokes is that they help people and processes work right the first time, which makes mistakes impossible to happen. These techniques can significantly improve quality and reliability of products and processes by eliminating defects. This approach to production fits perfectly the culture of continuous improvement, which is also part of the Lean management arsenal.
When and how to use it?
Poka Yoke technique could be used whenever a mistake could occur or something could be done wrong – meaning everywhere. It can be successfully applied to any type of process in manufacturing or services industry, preventing all kinds of errors:
• Processing error: Process operation missed or not performed per the standard operating procedure.
• 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.
•Measurement error: Errors in machine adjustment, test measurement or dimensions of
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