Poka-Yoke

INTRODUCTION:

Poka-Yoke is a Japanese term, which means fool proofing or mistake. Initially it was termed as Baka-Yoke. It is the basis of the Zero Defect Quality Control (ZQC) approach performed by Japanese companies. Poka-yoke is more of a concept than a procedure. It is a method for eluding mistakes. Mainly, this procedure is used in process of manufacturing but has many other uses, including Hospitals-drug dispensing, Invoice processing etc. Its goal is to attain zero defects. It is a system designed to arrest errors made by performers. This concept is widely use in Japan and other countries. Every customer has an authority to request 100% high quality product and every supplier has a responsibility to provide it. Bad quality products may harm the position.

METHODOLOGY

• Problem identification
• Survey at workstations
• Brainstorm for ideas
• Zero in on best idea
• Operational plan
• Execution
• Observe and sign-off

SOME ERROR-PROOFING APPROACH

• Make it difficult to generate the error
• Make it probable to alter the error
• Make it clear that the error has happened
• Discover variations from procedures
• Design
• Design process so it permits the error and result in zero defects.
• Design process to reduce complications.

APPROACHES TO MISTAKE PROOFING

CONTROL APPROACH:

• Cease the process when an error arise.
• High capacity of attaining zero defects.

WARNING APPROACH:

• Ask the operator to cease the procedure and inspect for a mess.
• Occasionally an automatic blockade is not an alternative.
• Lights, sounds and dials to generate attention to the mess.

Everyone can practice Poka-yoke in their working place. It doesn’t require any rocket science; it just entails common sense and proper Poka-yoke device.

A proper Poka-yoke device should have the following features.

• Easy to install
• Fit for use by all operators
• Doesn’t need constant observation from the worker (ideally, it should be automatic)
• Cheap
• Supplies quick feedback, preclusion and correction

EXAMPLES FROM OUR DAILY LIFE:

HOME:

Automatic shut-offs on electric coffee makers.

OFFICE:

Question evoke “Do you want to shut down” on your computer after clicking shutdown button.

IMPORTANCE:

Poka-yoke is the procedure that makes difficult to make errors. These processes make the products free of defects and improve standard and trustworthy. The use of Poka-yoke techniques in product and process design can make it free of any error. Poke-yoke doesn’t require being expensive. For instance, at every workstation, Toyota contains approximately 12 Poka-yoke devices and a goal of achieving each device for under $150.