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POKA YOKE
 Presented by:-
Krishna Singh
What is poka yoke ?
Poka yoke is mistake
proofing techniques.
Initially BAKA-YOKE
means fool-
proofing.
Changed to POKA-
YOKE means
mistake-proofing. Shigeo Shingo
(1960s)
Conti…
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.
Classification of poke yoke Poka
Yoke as Prevention Device:
Poka Yoke as Detection Device:
Conti….
What Causes Defects?
Errors lead to defects
Poor procedures or standards
Machines
Non-conforming material
Human Mistakes
TOUCH SWITCH
Floppy Disk
File cabinets, opening one
drawer locks all the rest
Photoelectric Vibration
Why is it important?
Helps people and processes.
Refers to techniques that make it impossible to make
mistakes.
Use the ideas and methods in product and process
design which can eliminate both human and mechanical
errors.
When to use it?
It is a technique, a tool that can be applied to any type of
process be it in manufacturing or the service industry.
Poka-yoke can be used wherever something can go
wrong or an error can be made.
Errors can be of any type-
 Processing Error: Process operation missed or not
performed per the SOP.
 Setup Error: Using the wrong tooling or
setting machine adjustments incorrectly.
Conti..
Missing Part: Not all parts included in the assembly,
welding, or other processes.
Improper part/item: Wrong part used in the process.
Operations Error: Carrying out an operation incorrectly;
having the incorrect version of the specification.
Measurement Error: Errors in machine adjustment, test
measurement or dimensions of a part coming in from a
supplier.
Step by step process in applying
poka-yoke:
Identify the operation or process
Decide the right Poka-yoke approach, such as
Shut out Type: Preventing an error being made.
Attention Type: Highlighting that an error has been made.
Characteristics of Poka Yoke
devices
Simple and cheap
Part of the process, permitting 100% inspection
Placed close to where the mistakes occur, providing quick
feedback
Designed to stop a particular mistake
A detection device cannot provide a complete error proof
solution
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
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
THANK
YOU

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Poka yoke

  • 1. POKA YOKE  Presented by:- Krishna Singh
  • 2. What is poka yoke ? Poka yoke is mistake proofing techniques. Initially BAKA-YOKE means fool- proofing. Changed to POKA- YOKE means mistake-proofing. Shigeo Shingo (1960s)
  • 3. Conti… 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. Classification of poke yoke Poka Yoke as Prevention Device: Poka Yoke as Detection Device:
  • 5. What Causes Defects? Errors lead to defects Poor procedures or standards Machines Non-conforming material Human Mistakes
  • 6. TOUCH SWITCH Floppy Disk File cabinets, opening one drawer locks all the rest Photoelectric Vibration
  • 7. Why is it important? Helps people and processes. Refers to techniques that make it impossible to make mistakes. Use the ideas and methods in product and process design which can eliminate both human and mechanical errors.
  • 8. When to use it? It is a technique, a tool that can be applied to any type of process be it in manufacturing or the service industry. Poka-yoke can be used wherever something can go wrong or an error can be made. Errors can be of any type-  Processing Error: Process operation missed or not performed per the SOP.  Setup Error: Using the wrong tooling or setting machine adjustments incorrectly.
  • 9. Conti.. Missing Part: Not all parts included in the assembly, welding, or other processes. Improper part/item: Wrong part used in the process. Operations Error: Carrying out an operation incorrectly; having the incorrect version of the specification. Measurement Error: Errors in machine adjustment, test measurement or dimensions of a part coming in from a supplier.
  • 10. Step by step process in applying poka-yoke: Identify the operation or process Decide the right Poka-yoke approach, such as Shut out Type: Preventing an error being made. Attention Type: Highlighting that an error has been made.
  • 11. Characteristics of Poka Yoke devices Simple and cheap Part of the process, permitting 100% inspection Placed close to where the mistakes occur, providing quick feedback Designed to stop a particular mistake A detection device cannot provide a complete error proof solution
  • 12. 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
  • 13. 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