MBA - 601

Total Quality
Management
Module 14:
TQM Tools- Poka-Yoke
or Mistake Proofing

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 Description
• Mistake proofing, fail saving, or its Japanese equivalent Poka-Yoke
(pronounced PO-ka yo-KAY).
• It is any mechanism in a lean manufacturing process that helps an
equipment operator avoid (yokeru) mistakes (poka).
• It is the use of any automatic device or method that either:
– Makes error impossible to occur or
– makes the error immediately obvious once it has
occurred.

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 Mistake proofing or Poka-Yoke
• The term poka-yoke was applied by Shigeo Shingo in the
1960s to industrial processes designed to prevent
human errors as part of the Toyota Production System.
• It was originally described as baka-yoke "fool-proofing"
(or "idiot-proofing") then name was changed to the
milder poka-yoke.
• https://www.youtube.com/watch?v=RdhJ5RQA8cU

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 How it is Developed
• The term poka-yoke was applied by Shigeo Shingo in the 1960s to
industrial processes designed to prevent human errors. Shingo
redesigned a process in which factory workers, while assembling a small
switch, would often forget to insert the required spring under one of the
switch buttons.
• In the redesigned process, worker would perform task in two steps,:
– first preparing the two required springs and placing them in a
placeholder
– then inserting the springs from the placeholder into the switch.
– When a spring remained in the placeholder, the workers knew that
they had forgotten to insert it and could correct the mistake
effortlessly.

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 How it is Developed
• Shingo distinguished between the concepts of:
– inevitable human mistakes
– and defects in the production.
• Defects occur when the mistakes are allowed to reach the
customer.
• The aim of poka-yoke is to design the process so that
mistakes can be detected and corrected immediately,
eliminating defects at the source.

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 When to Use
When to When human error can cause mistakes or defects to occur,
especially in processes that rely on worker’s attention, skill or
Use experience..
Mistake In a service process, where the customer can make an error
Proofing which affects the output

At a hand-off step in a process, when output or (for service

processes) the customer is transferred to another worker.

When a minor error early in the process causes major

problems later in the process

When the consequences of an error are expensive or

dangerous.

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 Mistake Proofing Procedure
• Obtain or create a flowchart of the process.
• Review each step, thinking about where and
when human errors are likely to occur.
• For each potential error, work back through
the process to find its source.

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 Mistake Proofing Procedure
• For each error, think of potential ways to make it
impossible for the error to occur. Consider:

Elimination
•eliminating the step that causes the error.

Replacement
•replacing the step with an error-proof one.

Facilitation
• making the correct action far easier than the
error.

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 Mistake Proofing Procedure
• If you cannot make it impossible for the error to occur, think
of ways to detect the error and minimize its effects. Consider:
– inspection method
– setting function
– regulatory function.
• Choose the best mistake-proofing method or device for each
error. Test it, then implement it.

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 Inspection Method
• Three kinds of inspection methods provide rapid feedback:

Successive Self-inspection Source inspection checks

inspection workers check before process step takes
is done at the their own work place, that conditions are
next step of the immediately correct. Often it’s automatic
process by the after doing it. and keeps process from
next worker. proceeding until conditions
are right

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 Setting functions
Methods by which a The contact or physical method:
Process parameter
Checks a physical characteristic such as diameter or
OR product attribute temperature, often using a sensor
is inspected for
errors:
The motion-step or sequencing method:
Checks the process sequence to make sure steps are done in
order.

The fixed-value or grouping and counting method:

Counts repetitions or parts or weighs an item to ensure
completeness.

Information enhancement:
Makes sure information is available and perceivable when and
where required.

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 Regulatory Functions
• Signals that alert the workers that an error has
occurred:
– Warning functions are bells, buzzers,
lights and other sensory signals.
Consider using color-coding, shapes,
symbols and distinctive sounds.
– Control functions:
• prevent the process from proceeding until the
error is corrected (if the error has already taken
place)
• or conditions are correct (if the inspection was a
source inspection and the error has not yet
occurred).

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 Video: Mistake Proofing: Achieving Zero Defects

• https://www.youtube.com/watch?v=TRbC9TjF
dhU

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 Mistake-Proofing Example
• The Restaurant Experience

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 Any Question

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