Poka Yoke

Introduction: Poka Yoke is a combination of two Japanese words, Poka meaning inadvertent errors & Yoke meaning to avoid and together they translate as error proofing as a work process system to eliminate inadvertent errors. Poka Yoke is a powerful and comprehensive tool for identification, measurement and analysis of mistakes at the Gemba (real place of work) and implementation of measures that prevent the activity from being incorrectly performed, thereby ensuring production of quality goods and services. Characteristics of Poka-Yoke: 1. Poka-Yoke is a fail safe mechanism for quality control. 2. Poka-Yoke proofing is powerful. 3. Poka-Yoke is simple. 4. Poka-yoke is inexpensive. 5. Poka-Yoke is a comprehensive method. 6. Poka-Yoke is an advanced aid in waste elimination. Key Principles: 1. Errors are inevitable but can be eliminated: - to err is human i.e. people make mistakes. These mistakes can be reduced or even eliminated. Poka-Yoke is a technique that can help to analyze these mistakes employees make and to eliminate these mistakes by implementing simple Poka-yoke devices.
2. To achieve quality: - Quality thus is a total approach involving everyone

in the organization and it is not just the responsibility of quality department.

3. Mistakes provide an opportunity for implementing and error reporting is

the fundamental step towards success: - One need not feel ashamed when a mistake is made but gracious enough to admit the mistake. Once mistake is admitted, solution becomes possible. If the mistake is not acknowledged, the people can persist identify. Mistakes should be publicly admitted so that others can learn from it avoid making such mistakes.
4. Errors are the result of inadvertent negligence of small little things by

some one in the chain: - Preventing mistakes prevents occurrence of

major ones. Poka-Yoke gives importance to these little things giving avenues for mistakes proofing.
5. Cent Percent inspection cannot ensure 100% quality: - Cent Percent

inspection cannot ensure 100% quality but building a low cost automated prediction methods for each process, to help operators to recognize the defect before it occurs, can achieve the feat.
6. The faster we discover the problem, the easier and less expensive it is to

correct: - The longer the discovering the problem, the higher is the cost. It makes sense to control the situation where the work is done, i.e. at the most upstream operation if not at the product design stage.