What is Poka-Yoke examples?

What is Poka-Yoke examples?

Poka-Yoke’s are mechanisms used to eliminate errors by effectively making it impossible to make mistakes in a given process. And they can be used everywhere. To give an example of Poka Yoke design – filing cabinets could fall over if too many drawers were pulled out at the same time.

What is Poka-Yoke concept?

Also called: poka-yoke, fail-safing. Mistake proofing, or its Japanese equivalent poka-yoke (pronounced PO-ka yo-KAY), is the use of any automatic device or method that either makes it impossible for an error to occur or makes the error immediately obvious once it has occurred. It is a common process analysis tool.

What is a Poka-Yoke connector?

A poka-yoke is any mechanism in a process that helps an equipment operator avoid (yokeru) mistakes (poka) and defects by preventing, correcting, or drawing attention to human errors as they occur. …

What are the golden rules of Poka-Yoke?

Poka-Yoke is a Japanese term that means “fail-safing” or “mistake-proofing.” The three golden rules associated with the term are: don’t accept a defect from the supplier; don’t make a defect; and don’t pass a defect onto the customer.

What are the 3 types of poka-yoke?

There are three types poka-yoke systems that can be used to fail-safe the server: task poka-yokes, treatment poka-yokes, and tangible poka-yokes.

What is poka-yoke PPT?

 Shigeo shingo defined poka-yoke as POKA- ‘Inadvertent mistake that anyone can make’ and YOKE- ‘To prevent or proof’  Poka-yoke is a tool to have “zero defects” and even reduce or eliminate quality control.  Poka-yoke is a Japanese name for “fool-proofing”.

Why poka-yoke is important?

Why is Poka-Yoke Important? The value of using Poka-Yoke is that they help people and processes work right the first time, which makes mistakes impossible to happen. These techniques can significantly improve the quality and reliability of products and processes by eliminating defects.

How do you create a poka-yoke?

5 Steps to Effective Poka-Yoke (Mistake-Proofing)

  1. Identify the appropriate type of error detection.
  2. Ensure that proper procedures are in place to act when a defect occurs.
  3. Implement a system for long-term learning from errors.
  4. Continuously develop the system.
  5. Get input from the operators themselves.

What are the benefits of poka-yoke?


  • elimination of set-up errors and improved quality.
  • decreased set-up times with associated reduction in production time and improved production capacity.
  • simplified and improved housekeeping.
  • increased safety.
  • lower costs.
  • lower skill requirements.
  • increased production flexibility.
  • improved operator attitudes.

What is Kaizen and poka-yoke?

Kaizen Objective. POKA-YOKE • ‘POKA’ : Mistake ‘YOKE’ : Proofing • A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). • Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

What percentage is Sixsigma?

Six Sigma quality – Six Sigma performance produces a defect-free product 99.99966% of the time; allowing only 3.4 errors per one million opportunities.

What is the disadvantage of poka-yoke?

Poka-Yoke Disadvantages The underlying motivation for using a poka-yoke method is the recognition that humans make mistakes, especially when performing repetitive processes. Additionally, if the poka-yoke measure is not well-designed, it may reduce efficiency and increase costs unnecessarily.