Corporate Training

Poka Yoke

Poke-yoke, a Japanese term meaning “mistake-proofing” or “error prevention”, refers to any mechanism in a process that helps prevent human errors. It’s a core concept in the Toyota Production System and is used in various industries to improve quality, efficiency, and safety.

Here are Some Common Types of Poke-Yoke Devices and Examples of How They are Used:

  • Prevention: These devices make it physically impossible to make an error. For example, a plug that only fits into one outlet or a car that won’t start without the seatbelt fastened.
  • Detection: These devices alert the operator to an error immediately after it occurs. For example, an alarm that sounds if a lid is not properly closed or a sensor that detects if a component is missing.
  • Information: These devices provide clear instructions or reminders to the operator. For example, labels that show how to assemble a product or color-coded components that must be matched.

Poke-yoke can be simple and low-cost, or more complex and automated. The most effective poke-yokes are designed to be foolproof and easy to use.

Here are some of the benefits of using poke-yoke:

  • Reduces errors and defects
  • Improves quality and consistency
  • Increases efficiency and productivity
  • Reduces rework and scrap
  • Improves safety
  • Boosts morale and job satisfaction