Poka Yoke is a Japanese term meaning "mistake-proofing" or "error-proofing". It is a quality control method used to eliminate or prevent mistakes or errors during manufacturing processes. The goal of Poka Yoke is to make it impossible or at least very difficult to make mistakes, thus improving efficiency and reducing defects. This can be achieved through various means, such as designing products or processes that are self-checking, using warning signals or alarms, or providing clear instructions for operators. By implementing Poka Yoke, organizations can improve the quality of their products and reduce the time and cost associated with fixing mistakes

1. POKA YOKE
MISTAKE PROOFING L ERROR PROOFING L FOOL
PROOFING L IDIOT PROOFING
GREENDOT.CO.IN

2. ABOUT US
GREENDOT IS A MANAGEMENT CONSULTING AND A TRAINING
FIRM. WE HELP OUR CLIENTS TO IMPROVE THEIR
PROFITABILITY, PRODUCTIVITY AND EFFICIENCY,
THROUGHBUSINESS PROCESS MANAGEMENT AS WELL AS BY
IMPLEMENTING STRATEGIES ANDPROVIDING TRAINING TO ALL
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COMPANY HAS UNIQUE NEEDS. WE CAN PROVIDE ASSISTANCE
AT ANY LEVEL FROMTHE EXECUTIVE OFFICES TO THE SHOP
FLOOR WITH STRATEGIC PLANNING THROUGH TACTICAL
IMPLEMENTATION.
GREENDOT IS FOCUSED ON BUSINESS PROCESS DESIGN.
EVERYTHING WE DO ISFOCUSED ON HOW AND COMPLIANT
PROCESSES YOUR PEOPLE CAN EXECUTE. WITHEXPERTISE OF
SINCE 1999 WE ARE ABLE TO EXPAND OUR SERVICE TO
CHINA,GERMANY, THAILAND AND MANY PARTS OF THE MIDDLE
EAST

3. 1
Program Contents
Poka Yoke Meaning
Defect and its IMPACT
Typical Errors
Why is “Zero Defects” an
Important Concept?
Six Principles of Poka Yoke
Benefits of Poka yoke
Poka Yoke Process
Type of Poka Yoke
Methods of Poka Yoke
Poka-Yoke Video
Poka Yoke Brain Teaser
What Makes a Good Poka Yoke
3 Rules of Poka Yoke
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4. POKA YOKE MEANING
If ERRORS can be prevented/eliminate,
DEFECTS will not be created
Poka-yoke is a quality assurance technique,
the aim of poka-yoke is to eliminate defects in
a product by preventing or correcting
mistakes as early as possible.
It was originally described as “ Baka yoke”, but
this name means “Fool Proofing” so the name
was changed to the Poka-yoke mistake-
proofing or more literally avoiding yokeru )
inadvertent errors poka
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5. DEFECT AND ITS IMPACT
Defect-free product is a necessity to compete
in the market
Every customer has a right to demand 100
good product services and every provider has
an obligation to provide the same
Bad products hurt both reputation and
bottom line (eg Scrap rework, warranty, etc
Defects have a direct impact on process yield
affecting the speed and flow of the product to
the customer
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6. TYPICAL ERRORS
Processing Errors
Missing Operation
Inappropriate Procedures
Missing Parts
Missing Information
Wrong Parts
Damaged Materials
Tools or Equipment Setup
Human Errors
Environmental Condition
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7. WHY IS “ZERO DEFECTS” AN
IMPORTANT CONCEPT
Maintain Customer Satisfaction & Loyalty Happy
Customers mean more sales!
COSTS
There is always a cost associated with
manufacturing defects!

8. SIX PRINCIPLES OF
POKA-YOKE?
Elimination
Prevention
Replacement
Facilitation
Detection
Mitigation
Principles
Redesigning the process or product
so that the task is no longer
necessary
Engineers the product or process so
that it is impossible to make a
mistake at all
Using robotics or automation
Color coding, combining steps, etc
Developing computer software that
notifies a worker when a wrong
input is made
Seeks to minimize the effects of
errors
How
PREVENTION OCCURRENCE
OF
HUMAN ERROR
MINIMIZE EFFECT AFTER
OCCURRENCE OF HUMAN
ERROR
PRINCIPLES
HOW

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Benefits of poka yoke
Eliminating defects
1 Detecting mistakes
Reduce customer complaints
Improving safety
Increaseproductivity
Reduced training time
Reduce inspection time
Reducing waste
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10. Don’t Accept Mistakes
INPUT
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Don’t Make Mistakes
2 PROCESS
Don’t Pass Mistakes
3 OUTPUT
POKA YOKE PROCESS

11. TYPE OF POKA YOKE
Control
Warning / Attention

12. CONTACT FIXED VALUE MOTION STEP
METHODS OF POKA YOKE
THREE METHODS

13. METHODS OF POKA
YOKE
It recognizes defects by testing the
physical attribute of the Product
Some type of device to identify defects in
a part's shape, size, color or other physical
attribute
Things like notches with matching locator pins,
interference pins, limit switches and proximity
switches are used to make certain a part is
positioned correctly before work begins
CONTACT

14. METHODS OF POKA
YOKE
Used in processes where the same action is
repeated several times
In other words, the fixed value method
alerts operators once a certain number of
movements has been made
FIXED VALUE

15. METHODS OF POKA
YOKE
Employed when a process requires several
different activities be completed in sequence by
the same operator The poka-yoke device for this
method is created to detect whether each
motion is performed and to alert the operator
when a step is skipped
A good example of a sequence poka-yoke device
is utilizing a simple proximity switch that opens
only after all components are loaded in the
correct order
MOTION STEP (THE SEQUENCE)

16. SUMMARY OF MISTAKE-
PROOFING TYPES
Contact
TYPE / METHOD
TYPE / METHOD
Parking height bars
CONTROL
CONTROL
Shop entrance bell
WARNING
WARNING
Fixed Value French fry scoop Trays with indentation
Motion Step Two hand control
on a press
Beepers on ATM

17. CAN YOU GUESS….?
CAN YOU GUESS….?
CAN YOU GUESS….?
ANS:
TYPE : CONTROL
METHOD : FIXED VALUE
HINT:
1. CONTACT: SIZE OR SHAPE
2. FIXED VALUE: NUMBER OF COUNTS
3. MOTION STEP:PROCESS SEQUENCE

18. CAN YOU GUESS….?
CAN YOU GUESS….?
CAN YOU GUESS….?
ANS:
TYPE : CONTROL
METHOD : CONTACT
HINT:
1. CONTACT: SIZE OR SHAPE
2. FIXED VALUE: NUMBER OF COUNTS
3. MOTION STEP:PROCESS SEQUENCE

19. CAN YOU GUESS….?
CAN YOU GUESS….?
CAN YOU GUESS….?
ANS:
TYPE : CONTROL
METHOD : CONTACT
HINT:
1. CONTACT: SIZE OR SHAPE
2. FIXED VALUE: NUMBER OF COUNTS
3. MOTION STEP:PROCESS SEQUENCE

20. CAN YOU GUESS….?
CAN YOU GUESS….?
CAN YOU GUESS….?
ANS:WARNING
HINT:
CONTROL OR WARNING

21. CAN YOU GUESS….?
CAN YOU GUESS….?
CAN YOU GUESS….?
Washing Machines only start when the
the door is closed and cannot be opened
until the cycle is over
Micro wave Oven does not work until
the door is shutr

22. ROBUST &
RELIABLE(CRITICAL
INEXPENSIVE
DEVELOPED WITH
THE USER SIMPLE
BASIC
SIMPLE BASIC
ENGINEERING
EASY TO
IMPLEMENTE
DOESN’T REQUIRE
CONTINUOUS
ATTENTION FROM
THE SUPERVISOR
SPECIFIC TO THE
NEED
WHAT MAKES A GOOD POKA
YOKE

23. 3 RULES OF POKA YOKE
Don’t wait for the perfect Poka-
Yoke . Do it
If your Poka-Yoke idea has a
better than a 50% chance to
succeed…Do it!
Do it now….improve later!
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24. CONTACT US
8141042060
info@greendot.co.in
www.greendot.co.in

25. THANK YOU