2. What is Poka-Yoke?
It is a Japanese term which means
“Mistake-Proofing”
It was originally known as Baka-Yoke,
which means “Fool-Proofing” / “Idiot-
Proofing”
It is mostly implemented in Manufacturing
Sectors
3. What is Poka-Yoke?
It is a Japanese term which means
“Mistake-Proofing”
It was originally known as Baka-Yoke,
which means “Fool-Proofing” / “Idiot-
Proofing”
It is mostly implemented in Manufacturing
Sectors
4. History:
This concept was first formalised and
adopted by Shigeo Shingo in 1961 as part
of the Toyota Production System
Shigeo Shingo applied this to prevent
human errors
He recognised the concept of unavoidable
human errors and defects in the
production
5. Why Poka-Yoke?
For operational excellence
Can prevent errors from occurring in the
first place
If this is not possible, it performs a
detective function, eliminating defects in
the process as early as possible
It ensures that proper conditions exist
before actually executing a process step
6. What is Error?
Error is a deviation from what is Correct,
Right or True.
Previously it was prevented by Scolding,
Retraining or Telling them to be more
careful.
Now it is prevented by Training & Motivation.
7. How to use Poka-Yoke?
Define the potential mistakes / errors
List them which could be transferred to the
next step
Combine them with other tools such as
Brainstorming
8. How to use Poka-Yoke?
Identify Root Causes
Investigate and analyze them
Use other tools such as 5 WHYs for this
step
9. How to use Poka-Yoke?
Preparation: Completely prepare the
team before they enter into the process
Encounter: Protect the team who may
misunderstand, ignore or forget their
nature of the job or their role
Resolution: Remind them of the value of
their input to the continuous improvement
of a service
10. How to use Poka-Yoke?
Task: Focus on the common mistakes
made while performing the task by the
team
Treatment: Focus on social interaction
with them
Tangible: Address the real, physical
impression and experience for the team
11. Benefits of Poka-Yoke
It helps people and processes work right
the first time
It is used to create a system that prevents
defects from occurring
It is used as a system to catch defects
It refers to techniques that make it
impossible to make mistakes
Its basic concept is to avoid the problems
by correcting the process
Notas del editor
In 1963, a worker at Arakawa Body Company refused to use baka-yoke mechanisms in her work area, because of the term’s dishonourable and offensive connotation. Hence, the term was changed to poka-yoke, which means ‘mistake-proofing’.
In 1963, a worker at Arakawa Body Company refused to use baka-yoke mechanisms in her work area, because of the term’s dishonourable and offensive connotation. Hence, the term was changed to poka-yoke, which means ‘mistake-proofing’.
#3. Typo is an unavoidable human errors but it happens when we type by looking at the keyboard. Secondly, the text can be spell-checked before delivery.