"Poka Yoke" is a Japanese lean manufacturing technique. It means to avoid mistakes and to form a defect free product or with 100% accuracy. In this presentation POKA YOKE system is explained which include three steps: awareness, root cause (5 why?) analysis, and six poka yoke techniques. Poka Yoke worksheet and its classification is illustrated with its approach, seven guidelines and advantages.

1. By –
Vishista Kaushik
M.Tech. (Production Engineering)

2. CONTENT
• Introduction
• Lean manufacturing
• Poka yoke
• Poka yoke system
• PY classification
• PY approach
• Seven guidelines
• Case study : HRC Assembly
• Advantages
• Conclusion
• References

3. Introduction
Desire
 Defect free
 Right to demand 100%
 Reputation and bottom line
 Direct impact
 Customer

4. Lean Manufacturing
PROBLEM TO ADDRESS LEAN TOOL TO USE
Lack of a plan Value stream mapping
Problem solving Kaizen events
Workplace organization The 5S system
Material flow issues Spaghetti diagram
Stability issues, Defects, Errors,
Accidents
TPM ( Total Productive Maintenance),
Poka –Yoke (Mistake Proofing), Quick
Changeovers
Process flow issues Task/cycle times, Standardized work, Lean
cell design, Workload balancing, Batch size,
One – piece flow, Quality at the source
Supply (Pull) issues Kanban, Point-Of-Use-Storage (POUS)
Pursuit of perfection Kaizen principles, Workplace practices

5. Poka Yoke
ポカ = Poka : Mistakes ヨケ = Yoke : Avoid
• Objective : To achieve Zero Defects
• Originally known as “ Baka Yoke” means fool proofing
• Adopted by Toyota Production System in 1960.

6. Examples of poka yoke
Figure 1: Plug Pointer Figure 2: Traffic Signal
[1] https://www.pinterest.com/pin/57983913939945047/
[2] https://www.itsinternational.com/its8/feature/what-actually-happens-if-we-do-freethemibs

7. Examples of poka yoke
Figure 3: Phone Battery Figure 4: Wash Basin
[3],[4] https://www.slideshare.net/sanjaysanthakumar9/poka-yoke-131123646

8. Poka yoke system
1) Awareness
2) Root Cause Analysis
3) Solution to address cause : Six Poka Yoke techniques

9. 1. Awareness
 Brainstorm
 Communicate possible errors
 Measure actual errors
 Run charts
 80/20 Rule (or) 10-100 Rule
 Routinely review performance

10. 2. Root cause analysis
 List the mistake/error
 Why the problem occurs
 Record all possible answers
 Ask why (approximately 5 levels) and to get true root cause
 “Can we fix this problem?”
 Draft practical solution

11. The 5 Why’s Worksheet
Description of the
incident:
Why did the incident occur?
Why? Why? Why?
Why? Why? Why?
Why? Why? Why?
Why? Why? Why?

12. 3. Solution to address cause
Elimination Replacement
Prevention
Facilitation
Detection Mitigation
The six poka yoke system techniques are as follows:

13. Poka Yoke Worksheet
Description of the Incident:
Top three causes for the incident
Poka Yoke Solution
Elimination: Can the activity be
eliminated?
Replacement: Can the activity be
automated?
Prevention: Can the mistake be
physically prevented?
Facilitation: Can visual controls be
utilized?
Detection: How can the mistake be
immediately detected?
Mitigation: How can the effect of
the mistake be minimized?

14. Poka -Yoka classification
Poka Yoke
Server Poka Yoke Customer Poka Yoke
Task
Tangibles
Treatment
Resolution
Encounter
Preparation

15. Approaches to poka yoke
 Control Approach  Warning Approach
>> Signals the operator to stop
the process
>> Dials, lights, and sounds to
bring attention to the
problem
Fig 1: Electronic door
locks can have three
mistake-proofing devices
[1] https://www.slideshare.net/sanjaysanthakumar9/poka-
yoke-131123646

16. Seven Guidelines for PY Attainment
 Quality processes
 Utilize a team environment
 Elimination of errors
 Eliminate the root cause of error
 Do it right the first time
 Eliminate non value added decisions
 Implement an incremental continual improvement approach

17. Case study
CASE NO. 1 : PY in Human – Robot Collaborative Assembly
• Need : Demand of the hour
• Objective: To minimize the possible error
• Procedure:
• Step 1: Mistake identification
• Step 2: Mistake prevention
• Step 3: Assignment of tasks and assessment

18. Proposed PY solution for HRC assembly

19. Proposed task sequence by D. Antonelli [1]

20. Advantages
 100% assessment.
 Discovers and eradicates defects.
 Consecutive verification
 Self-check actions and quicker review
 Eliminates the causes
 Increases customer satisfaction.
 Waste reduction in defects

21. Conclusion
Poka-yoke deals with understanding why people make errors and
how to analyze the process to know where errors are likely to
occur and what root causes contribute to them.
Using poka yoke results in increase in the productivity with
minimum waste and zero defect position.

22. References
• D. Antonelli, D. Stadnicka. Predicting and preventing
mistakes in human – robot collaborative assembly - IFAC
Paper Online.2019;50:13:734-748
• D. Antonelli, D. Stadnicka. Classification and efficiency
estimation of mistake proofing solutions by fuzzy inference-
IFAC PaperOnLine.2016;42:12:1134-1139
• Soni Pankaj, Yadav Tarun. Review paper on productivity
improvement by using poka yoke – International research
journal of engineering and technology.2018;05:12:761- 763

23. • Patil S. Parikshit, Sangappa P. Parit. Review paper on “poka
yoke: the revolutionary idea in total productive management”
– International journal of engineering and
science.2013;02:04:19-24
• Biswas Sujay, Chakraborty Abhijit. Using Poka Yoke for the
development of SMEs – American Journal of Engineering
Research.2016;05:09:15-18
• Milovan Lazarevic, Jovan Mandic. A systematic literature
review of poka yoke and novel approach to theoratical aspects
– journal of mechanical engineering Slovenia. 2015;01:1-16

24. “ ありがとうございました ”