What Does POKA YOKE Mean????

Poka Yoke

INADVERTANT YOKURE
ERROR (TO AVOID)
(Mistake) (Proofing)

SIOM | Symbiosis Institute of

Operations Management, Nashik
Poka Yoke
• ‘Poka’ means ‘Mistakes’ & ‘Yoke’ means ‘Avoid’. It’s objective is to
achieve Zero Defects.

• 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.

• Term adopted by Dr. Shigeo Shingo as part of the Toyota Production

System in 1960.

• It was originally described as “baka-yoke”, but this name mean “Fool-

Proofing” so the name was changed to the Poka-yoke.

SIOM | Symbiosis Institute of

Operations Management, Nashik
Typical Errors
 Processing errors  Wrong parts

 Missing Operation  Damaged materials

 Inappropriate procedures  Tools or equipment

improperly prepared or
setup
 Missing parts

 Human Errors
 Missing information

SIOM | Symbiosis Institute of

Operations Management, Nashik
DEFECTS AND ITS IMPACT
• Defect free product is a necessity to compete in the market
place.
• Every Customers has a right to demand 100% good product
/service and every provider has an obligation to provide the
same.

• Bad products hurt both reputation and bottom line (Scrap,

rework, warranty….etc.,.)

• Defects have a direct impact on process yield affecting speed

and flow of the product to the customer.

SIOM | Symbiosis Institute of

Operations Management, Nashik
METHODOLOGY
• Identify a problem
• Observations at workstation
• Brain storm for ideas
• Zero in on best idea
• Implementation plan
• Implement
• Monitor & Sign-off

SIOM | Symbiosis Institute of

Operations Management, Nashik
Why is “Zero Defects” an Important
Concept?
Maintain Customer Satisfaction & Loyalty
• Happy Customers mean more sales!

COSTS
There is always a cost
associated with
manufacturing defects!

SIOM | Symbiosis Institute of

Operations Management, Nashik
DEFECT DETECTION AND
PREVENTION STRATEGIES
Feedback Feedback Feedback
Finished Successive
Inspect

Inspect

Inspect
Process Process Process Goods/
A B B Shipping Checks

• Each process inspects previous process

• Typically, 3 or less critical checks per step
• Effective with small transfer quantities from process to
process.

Feedback Feedback Feedback

Finished
Inspect

Inspect

Inspect
Process Process Process
A B B
Goods/ Self-Checks
Shipping

• Find defects as they exit process, Immediate feedback & corrective action.
• Stops adding value to defective product.

Prevent the defect from occurring in the first place

or to make it immediately evident Poka-Yoke

SIOM | Symbiosis Institute of

Operations Management, Nashik
SOME MISTAKE-PROOFING STRATEGIES

 Make it harder to create the error

 Make it possible to reverse the error

 Make it obvious that the error has occurred

 Detect deviations from procedures or fixed values (e.g., Number of

parts)

 Design:

 Design process so it tolerates the error and doesn’t result in a defect

 Design process to decrease complexity
SIOM | Symbiosis Institute of
Operations Management, Nashik
APPROACHES TO MISTAKE PROOFING
 Control approach

 Shuts down the process when an error occurs

 High capability of achieving zero defects (ie robust design that can tolerate variation or
eliminates variation or assembly mistakes)

 Warning approach

 Signals the operator to stop the process and correct problem or check for a problem (ie
are parts still ok, is oil level ok)

 Sometimes an automatic shutoff is not an option

 Dials, lights, and sounds to bring attention to the problem

SIOM | Symbiosis Institute of

Operations Management, Nashik
EXAMPLES OF SOME USEFUL MISTAKE-PROOFING DEVICES

• Guide pins, to assure that parts can only be

assembled in the correct way.
• Limit switches, that sense the presence or absence of
a part.
• Mistake-proofing jigs, detect defects immediately
upstream of the process ensuring that only the correct
part reach the process.
• Counters, that verify that the correct number of parts
or steps have been taken.
• Checklist, that reminds operators to do certain
actions.

SIOM | Symbiosis Institute of

Operations Management, Nashik
EVERYDAY EXAMPLES OF MISTAKE PROOFING
• Home
– Automated shut-offs on electric coffee pots
– Child-Proof caps on mediations
– Ground fault circuit breakers for bathrooms or outside electric circuits
• Office
– Spell check in word processing
– Question prompt “Do you want to delete?” after pressing the “Delete” button on
your computer.
• Factory:
– Dual palm button and light curtains on machines “I have an
• Retail: extra part.
I must
– Tamper-Proof packaging
have
– Bar coding at checkout. omitted a
step!”

SIOM | Symbiosis Institute of

Operations Management, Nashik
Mistake Proofing Devices
• Types of mistake proofing devices within control or warning approach can be of:
– Contact type:
• The contact type makes contact with every product or has a physical shape
that prevents mistakes.
– Example: Fixed diameter hole through which all products must fall and
an oversize product does not fall through and a defect is registered.
– Fixed value type:
• The fixed value method is a design that makes it clear when a part is missing
or not used.
– Example: “Egg tray” used for supply of parts,
– Motion step type:
• The motion step type automatically ensures that the correct number of steps
have been taken.
– Example: An operator is required to step on a foot pedal every assembly
cycle, Correct sequence for switches that do not work unless the order is
correct.

SIOM | Symbiosis Institute of

Operations Management, Nashik
TYPES OF SENSING DEVICES
Sensing devices that are traditionally used in poka-yoke systems
can be divided into three categories:
1. Physical contact devices
2. Energy sensing devices
3. Warning Sensors

Each category of sensors includes a

broad range of devices that can be used
depending on the process.

SIOM | Symbiosis Institute of

Operations Management, Nashik
PHYSICAL CONTACT SENSORS
These devices work by physically
touching something.

This can be a machine part or an

actual piece being manufactured.

In most cases these devices send an

electronic signal when they are
touched.

Depending on the process, this

signal can shut down the operation
or give an operator a warning signal.

SIOM | Symbiosis Institute of

Operations Management, Nashik
TOUCH SWITCH
Used to physically detect the presence or absence of an object or
item-prevents missing parts.
Used to physically detect the height of a part or dimension.

SIOM | Symbiosis Institute of

Operations Management, Nashik
ENERGY SENSORS
These devices work
by using energy to
detect whether or
not an defect has
occurred.
Fiber optic

Vibration Photoelectric

SIOM | Symbiosis Institute of

Operations Management, Nashik
WARNING SENSORS
Warning sensors signal the
operator that there is a
problem.
Color Code

These sensors use colors,

alarms, lights to get the
workers attention !
Lights

These sensors may be Lights connected

used in conjunction with a to Micro switches
contact or energy sensor to & timers
get the operators attention.

SIOM | Symbiosis Institute of

Operations Management, Nashik
SET A STANDARD
• Errors are not acceptable

• Use cross-functional teams to design and maintain processes to be

robust

• RIGHT FIRST TIME

– Good: Design products and processes so that we make it right the first time

– Best: Design products and processes so we CAN’T make it wrong any time and
get a concurrent productivity improvement

SIOM | Symbiosis Institute of

Operations Management, Nashik
ADVANTAGES
• 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
reliability

SIOM | Symbiosis Institute of

Operations Management, Nashik
LIMITATIONS
• Requires special expertise in terms of
instrumentation knowledge
• 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 the company

SIOM | Symbiosis Institute of

Operations Management, Nashik
SIOM | Symbiosis Institute of
Operations Management, Nashik