Poka-Yoke By Amit, Hyderabad, India
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Poka-Yoke
By Amit, Hyderabad, India
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
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
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
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
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.
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
How to use Poka-Yoke?
Identify Root Causes
Investigate and analyze them
Use other tools such as 5 WHYs for this step
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
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
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
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