Poka-Yoke is a method used in
the workplace to prevent common human error.
It is also known as mistake-proofing and fail safe work method.
The aim is to eliminate defects in the product by
avoiding, fixing, or drawing attention to human errors when they happen.
History of Poka- yoke:
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 process design.
Examples of Poka-yoke:
One of the most common is when a driver of car with a manual Gear box must press the clutch pedal before starting the engine.This interlock prevents from an unintended movement of a car.
Why is Poka-yoke important?
The value of using Poka-yoke is that they help people and processes work right the first time, which make mistakes impossible to happen.
These techniques can significantly improve quality and reliability of the products and processes by eliminating defects.
"The application of basic ideas and methods to Poka Yoke in
product and process design will remove both human and mechanical errors."
Steps of Poka yoke Implementation:
1.Identify Problems
2. Prioritise
3.Seek Root cause
4.Find and implement solutions
5.Measure the results
Six Poka yoke Techniques for Error proofing:
1.Elimination
2.Replacement
3.Prevention
4.Facilitation
5.Detection
6.Mitigation
Benefits of Poka Yoke:
1.Elimination of set up errors and improved quality.
2.Decreased set up times with associated reduction in production time and improved production capacity.
3.Simplified and improved housekeeping.
4.Increased Safety.
5. Lower costs.
6. Lower skill requirements.
7. Increased production flexibility.
8. Improved operator attitudes.
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