Quality Tools Example: Poka Yoke
Poka-yoke is a Japanese term that means "mistake-proofing".
A poka-yoke is any mechanism that helps an equipment operator avoid (yokeru) mistakes
(poka). Its purpose is to eliminate product/service/process defects by preventing, correcting,
or drawing attention to human errors as they occur.
The concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota
Production System.
Firstly, it was described as baka-yoke, but as this means "fool-proofing" (or "idiot-proofing")
the name was changed to the milder poka-yoke.
Poka Yoke Definition
http://pokayoke.wikispaces.com/
http://en.wikipedia.org/wiki/Poka-yoke
Poka Yoke Examples
http://www.baddesigns.com/examples.html
http://www.baddesigns.com/examples.html
Find 20 examples of Poka Yoke solutions
for enterprises/organizations “everyday situations”
(An example in page 3)
Send one document to The Campus Virtual before
14th of November
VR_MAD002 Quality Control: Six sigma http://www.vrtuosi.com
Poka Yoke Visual “antiques” Examples
1. Envelope Window
Photo Description
The window in the envelope is not only a labour saving device. It
prevents the contents of an envelope intended for one person
being inserted in an envelope addressed to another.
2. Diskette
3.5 inch diskette cannot be inserted unless diskette is oriented
correctly. This is as far as a disk can be inserted upside-down.
The bevelled corner of the diskette pushes a stop in the disk drive out
of the way allowing the diskette to be inserted.
This feature, along with the fact that the diskette is not square, avoid
incorrect orientation.
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Evaluation
Before - After: Now you can see one everyday mistake example.
Pay attention to the example, observe the difference between the before and the after
situation. Wee think that is a good solution for the initial design mistake.
Stove A
Which control operates each burner?
Note: Operater must reach over burners to reach some controls.
Stove B
Association between each control and burner is obvious.
http://www.assuredquality.com/example_2.htm
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References
Books
1. Shingo S. “Zero Quality Control: Source Inspection and the Poka-yoke System”.
Productivity Press.
2. Shingo S. “The Poka-Yoke System I Theory”. Productivity Press.
3. Shingo S. “The Poka-Yoke System II: Practical Applications”. Productivity Press
4. Vasilash G.S. “On training for mistake-proofing”. ProQuest ABI/INFORM
5. Chase R.B. and Stewart D.M. “Make your service fail-safe”. ProQuest ABI/INFORM
6. Myers M. “Poka/yoke-ing your way to success”. ProQuest ABI/INFORM
7. Snee R.D. “Creating robust work processes”.
8. Shimbun N.K. “Poka Yoke: Improving Product Quality by Preventing Defects”. Factory:
Magazine, Productivity Press.
Web Sites
1. http://www.mistakeproofing.com/example1.html
2. http://facultyweb.berry.edu/jgrout/everyday.html
3. http://www.poka-yoke.org.uk/
Videos
1. Poka-yoke Manufacturing
http://www.youtube.com/Gluska
2. Poka-yoke Clip - Mistake Proofing to Achieve Zero Defects
http://www.youtube.com/watch?v=p7VFcC4sNY4
3. Flexible Manufacturing line with data tracking
http://www.youtube.com/watch?v=cb-I4FhF36Q
4. Poka-Yoke Screen System
http://www.youtube.com/watch?v=7loCwYg6uqU
5. Poka Yoke: Mistake Proofing
http://www.youtube.com/watch?v=2RthkxGwFsU&feature=related
VR_MAD002 Quality Control: Six sigma http://www.vrtuosi.com