POKA-YOKE OR MISTAKE PROOFING

-AN OVERVIEW

Ashish Gupta
Asst. Officer QA
Parle Biscuit Pvt. Ltd., Pantnagar(Uttarakhand)
 “Be more careful” not effective
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 The old way of dealing with human error was to scold people,
retrain them, and tell them to be more careful… My view is that you
can’t do much to change human nature, and people are going to
make mistakes. If you can’t tolerate them... you should remove the
opportunities for error.

 Training and motivation work best when the physical part of the
system is well designed. If you train people to use poorly designed
systems, they’ll be OK for awhile. Eventually, they’ll go back to what
they’re used to or what’s easy, instead of what’s safe.

 You’re not going to become world class through just training, you
have to improve the system so that the easy way to do a job is also
the safe, right way. The potential for human error can be
dramatically reduced.
 What Causes Defects?
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c Poor procedures or standards.

o Machines.
o Non-conforming material.
a Worn tooling.
a Human Mistakes.

Except for human mistakes these conditions can be

predicted and corrective action can be
implemented to eliminate the cause of defects.
 What to do now!!!
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To avoid such mistakes here comes the tool that is

called…
Mistake-proofing systems

Does not rely on operators catching mistakes

Inexpensive ‘Point of Origin inspection’

Quick feedback 100% of the time

 What is it?
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Poka-yoke (pronounced POH-kah YOH-kay) was coined in

Japan during the 1960s by Shigeo Shingo who was on of
the industrial engineers at Toyota.

The initial term was ‘baka-yoke’, which means ‘fool-

proofing’. This term ‘baka-yoke’ dishonorable and offensive
connotation. Hence, the term was changed to poka-yoke,
which means ‘mistake-proofing’.
 What the Poka-yoke is?
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 Techniques that help operators avoid mistakes in

their work caused by choosing the wrong part,
leaving out a part, installing a part backwards, etc.
 It involves the implementation of fail-safe ways
methods that detect or prevent human and machine
error at or near the source.
 It provides instant feedback and prevention of
quality problems
 Poka-Yoke as a…
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Poka Yoke as Prevention Device

Is a device or process that prevents errors from
occurring or prevents these errors from creating defects.
Examples: part locators, part present sensors.

Poka Yoke as Detection Device

Is a device that will detect a defect or concern and
initiate a corrective action.
Examples: vision system, limit sensors
 Why is it important?
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 Poka-yoke helps people and processes work right

the first time.
 Poka-yoke refers to techniques that make it
impossible to make mistakes.
 Poka-yoke techniques can drive defects out of
products and processes and substantially improve
quality and reliability.
 It can be thought of as an extension of FMEA.
 Contd…
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 It can also be used to fine tune improvements and

process designs from six-sigma Define - Measure -
Analyze - Improve - Control (DMAIC) projects.

 The use of simple poka-yoke ideas and methods in

product and process design can eliminate both
human and mechanical errors.
 When to use it?
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 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.
 Contd…
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 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. 
 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.  
 How to use it?
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Step by step process in applying poka-yoke:

2. Identify the operation or process - based on a Pareto Analysis.
3. Analyze the 5-whys and understand the ways a process can
fail.
4. Decide the right Poka-yoke approach, such as using a,
 Shut out Type: Preventing an error being made, or an
 Attention Type: Highlighting that an error has been made.

Note: Take a more comprehensive approach instead of merely thinking of

Poka-yoke as limit switches, or automatic shutoffs. A poka-yoke can be
electrical, mechanical, procedural, visual, human or any other form that
prevents incorrect execution of a process step.
 Contd…
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1. Determine whether a
 ContactMethod
 Constant Number or Counting Method
 Motion-Sequence Method

2. Trial the method and see if it works.

3. Train the operator, review performance and
measure success.
 Methods in Detail
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Contact Methods
“Do not have to be high tech!”
 Passive devices are sometimes the best method. These
can be as simple as guide pins or blocks that do not
allow parts to be seated in the wrong position prior to
processing.
 Take advantage of parts designed with an uneven
shape!
 A work piece with a hole a bump or an uneven end is a
perfect candidate for a passive jig. This method signals
to the operator right away that the part is not in proper
position.
 Methods in Detail
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Constant Number or Counting Method

 Used when a fixed number of operations are required within a
process, or when a product has a fixed number of parts that are
attached to it.
 A sensor counts the number of times a part is used or a process is
completed and releases the part only when the right count is
reached.

Motion-Sequence Method
 The third poka yoke method uses sensors to determine if a motion or
a step in a process has occurred. If the step has not occurred or has
occurred out of sequence, the sensor signals a timer or other device
to stop the machine and signal the operator.
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Day2Day Examples of
Poka-Yoke
 Day2Day Example
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3.5 inch diskettes cannot be inserted unless diskette is

oriented correctly. This is as far as a disk can be inserted
upside-down. The beveled corner of the diskette along with
the fact that the diskette is not square, prohibit incorrect
orientation.
 Day2Day Example
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For some file cabinets, opening one drawer locks all the
rest, reducing the chance of the file cabinet tipping.
 Day2Day Example
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Circuit breakers prevent electrical overloads and

the fires that result. When the load becomes too
great, the circuit is broken.
 Day2Day Example
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Even bathroom sinks have a mistake-proofing

device. It is the little hole near the top of the sink
that helps prevent overflows.
 Day2Day Example
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Both the sink and the urinal are fitted with light
sensors. These sensors insure that the water is turned
off in the sink and that the urinal is flushed.
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Okay, So This Is Not An Everyday

Example For Anybody. I Hope
You'll Find It Interesting
Nonetheless…
 Bathyscaph Submarine
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The bathyscaph is a deep water submarine used to explore the very lowest parts of
the ocean. It is electrically powered. Once at the bottom, if the batteries or
electrical system fail the best outcome would be for the sub to return to the surface.
The designers made this outcome occur by holding the ballast in place with
electromagnets. When power is lost, the ballast drops off automatically and the sub
starts its ascent.
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Any Questions???

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Thanks For
Keeping Patience
