“Poka Yoke”

or
QUALITY BY MISTAKE PROOFING DESIGN
AND CONSTRUCTION SYSTEMS

IGLC16, Manchester, UK, 16-18 July 2008

Iris D. Tommelein
Project Production Systems Laboratory
http://p2sl.berkeley.edu/

1
Shigeo Shingo (1986)
Zero Quality Control: Source Inspection and the Poka-Yoke System

Paraphrased”
“Inspection and statistical
quality control come too
late in the process to
totally eradicate all quality
problems.”
Quality must be tackled
up-front. Quality must be
built into each process.
feedback
to
worker
? COMMISSIONING
REPORT LAWSUIT

FOREMAN GC OPERATION
FAILURE
PUNCHLIST
WORKER INSPECTOR SNAGLIST
AEC Examples of Mistake-proofing
Color Coding Drawings/BIM

(Source: DPR, Inc., Camino Medical Project)

AEC Examples of Mistake-proofing
Color Coding on Site
Color coding shows
locations for sheet
metal straps and pipe
hangers.

Source: John Mack, Southland Ind., presentation at

2007 LCI Ann. Conf.
Mistake Proofing to Accommodate
Dimensional Variation

Connect plug and wiring

of light fixtures
(Source: Finelite product literature)
Flexible hose
(Source: Picture by Iris D. Tommelein,
Boston, MA, 2007)
Mistake Proofing to
Accommodate Oversight

Wiring plug for ballast Instruction label

inside light fixture on outside of
(Source: Picture by Iris D. Tommelein taken at Finelite,
fixture
(Source: Picture by Iris D.
Union City, CA, 2008) Tommelein taken at Finelite,
Union City, CA, 2008)
 Roofing sealant groove
Preformed sealant grooves and guides in system panels
promote accurate sealant placement between panels.

Source: http://www.butlermfg.com/images/level3_pages/returnleglink-large.jpg visited 5/23/06.

Sketch with Plan View of Sketch with Side View of
Sink Layout with Sloping Sink, Drain, and
Floor and Drain Exaggerated Sloping Floor
‘Bare’ Sink in San ‘Dressed-up’ Sink in
Francisco Airport, Mich. State Univ. Conf.
California Center, East Lansing,
(© 2006 Iris D. Tommelein)
Michigan
(© 2007 Iris D. Tommelein)
Sink with Covered Apron in Brussels Zaventem
Airport, Belgium (© 2007 Iris D. Tommelein)
Swing-away apron Provides
Clearance

Source: Photo by Iris D. Tommelein, Oakland Airport.

Why use Poka Yoke?

Eliminate Process Variation

– Make work more standard
• Ease of training
• Ease of identifying improvement opportunities
– Improve Reliability of Quality
– Reduce Process Time and make Time more
Reliable
• No rework
– Improve Safety Performance
ALL ESSENTIAL PARTS TO TOYOTA
PRODUCTION SYSTEM
 Seeking Examples in AEC

Catalog of 150 examples from

medical professionals around
the country.

Published in May 2007 by the

US Government (AHRQ, HHS).

Æ Will you contribute to

developing such a guide
with AEC examples?
Table saw safety now:
blade guard
Table saw safety next: SawStop

What other design changes could be implemented in AEC?