Implementing Poka-Yoke, or error-proofing techniques, in an organization can bring about a profound and emotionally uplifting transformation. Let us dive into how this approach can create a positive and empowering atmosphere. There is the incredible sense of reliability and quality assurance. When you utilize Poka-Yoke methods, you are essentially putting in place a system that catches errors before they become major issues. This leads to products and services that are consistently of high quality, which in turn builds a great deal of trust among your customers. They feel cared for and valued because they see that your business is committed to delivering excellence. In summary, Poka-Yoke is much more than a set of techniques to reduce errors; it is a pathway to creating an emotionally fulfilling, trust-rich, and quality-focused business environment. It is about building an organization that not only thrives in its operations but also creates a resonant emotional connection with its employees and customers.

1. Thought Leadership Series
POKA-YOKE
Error Proofing
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2. ©Quantum Associates, Inc 2023
Poka-Yoke
• Poka – Inadvertent Yokeru --To Avoid
Also known as:
• mistake proofing
• error proofing
• Primary component in Zero Quality
Control is a systematic approach to
eliminating the possibility of a mistake
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3. Two Approaches to DealWith Errors
• Errors are inevitable --They may be detected in final inspection or,
worse case, by the Customer
• Errors can be eliminated -- Any mistake people can make can be
reduced or even eliminated
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4. Errors
• What kind of errors are there?
• Are they unavoidable?
• What is the relationship between defects and human errors?
• Is sampling inspection the best method?
• Are there strategies to follow to move towards zero errors?
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5. What is the Difference Between Errors
& Defects?
Is there one?
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6. Error Defect
Defect?
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7. Error or Defect?
• FUEL LEAK ON FUEL PUMP?
• CHIP DETECTOR & PLUG INSTALLED INWRONG PORTS ON
GEARBOX MODULE
• BOLT 650869 INSTALLED INWINDOW REGULATOR INSTEAD OF
BILL OF MATERIAL BOLT, ST1411-07
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8. DEFECTS
DAMAGED
PARTS
CONTAMINATED
LUBRICANTS
POOR
DIMENSIONS
WRONG
PARTS OR
MATERIAL
BAD INCOMING
MATERIAL
UNABLE TO
ASSEMBLE
INCONSISTENT
TEST RESULTS
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9. IS ABOUT TO OCCUR
WARNING
WHEN A DEFECT
HAS OCCURRED
MISTAKE-PROOF DEVICE
MISTAKE-PROOF DEVICE
SIGNALS MISTAKE
IS ABOUT TO
OCCUR
CONTROL
EVEN INTENTIONAL
ERRORS ARE
IMPOSSIBLE
SHUTDOWN
OPERATIONS
STOP WHEN
DEFECT PREDICTED
WARNING
SIGNALS
DEFECT HAS
OCCURRED
CONTROL
DEFECTIVE PARTS
CAN NOT PASS ON
SHUTDOWN
OPERATIONS
STOP WHEN
DEFECT DETECTED
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10. Three InspectionTechniques
• Judgment -- Separate defective from good product after processing.
• Informative -- Investigates causes of defects and provides feedback
to process(s) for action to reduce defects.
• Source -- Checks for factors that cause errors, not the resulting
defect. Supports 100% inspection.
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11. Is 100% InspectionThe Best Method?
• World class manufacturers have zero tolerance for defects
• Production is organized to support 100% inspection
• Even one defect can destroy consumer confidence in a company!!!
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12. IT’S EASY FOR USTO BLAMETHE
PEOPLE WHO MAKE MISTAKES
BUTWE SHOULD BE LOOKING CLOSER
ATTHEWAYWE EXPECTTHEMTO
WORK.
Don’t Play the Blame Game
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13. Intentional
Misunderstanding
Forgetful
Misidentification
Amateurs
Willful
Inadvertent
Slowness
Non-Supervision
Surprise
Omittedprocessing
Processing errors
Errors setting up
workpieces
Missing parts
Wrong parts
Processing wrong
workpiece
Misoperation
Adjustment error
Equipment not set up
properly
Causes of
Defects
Human
Errors
Causal Relationship
Between Defects and Human Errors
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14. ©Quantum Associates, Inc 2023
The Basic Functions of Poka-Yoke
• Defects fall into one of two states:
• Prevention -- defects which are about to occur
• Detection -- defects which have already occurred
• Poka-Yoke has three functions
• Shutdown -- stop when defect is predicted or detected
• Control -- prevent defects from occurring or from
passing to next process
• Warning -- signals that defect is predicted or detected
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15. What is the Difference Between Prevention &
Detection?
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16. ©Quantum Associates, Inc 2023
PREVENTION DETECTION
What is the Difference Between
Prevention & Detection?
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17. Mistake-Proof Devices
You Should be Able to AnswerYes to All of
These
* PREVENTS REOCCURRENCE?
* LOW COSTTO IMPLEMENT?
* MADEWITH EXPERIENCE & INGENUITY?
* SIMPLETO USE?
* EASYTO IMPLEMENT?
* EASYTO MAINTAIN & DURABLE?
* DOES NOT HINDER OPERATOR?
YES NO
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18. Everyday Examples
Fueling area of car has three error-proofing devices:
1. insert keeps leaded-fuel nozzle from being inserted
2. tether does not allow loss of gas cap
3. gas cap has ratchet to signal proper tightness and
prevent overtightening.
New lawn mowers are required to have a safety bar
on the handle that must be pulled back in order
to start the engine. If you let go of the safety bar,
the mower blade stops in 3 seconds or less.

19. Poka-yoke Hints
• Identify items by their characteristics
• weight, dimension, shape
• Detect deviation from procedures or omitted processes
• subsequent work cannot be performed if previous work did not
follow procedures
• Detect deviations from fixed values
• Use of counter, critical condition detection, Odd-part-out method
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20. ©Quantum Associates, Inc 2023
Devices for Poka-Yoke
• Contact devices
• Micro/ limit/ proximity switches
• Displacement sensors, etc.
• Non-contact devices
• Photoelectric transmission cells
• Reflection switches
• Magnetic sensors
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21. Types of Mistake-Proof Devices
 TEMPLATE
 SWITCH
 COUNTER
 ODD-PART-OUT
 SEQUENCE RESTRICTION
 STANDARDIZE
 CRITICAL CONDITION INDICATOR
 GUIDE
 STOPPER/GATE
 SENSOR
 MISTAKE-PROOFYOUR MISTAKE-PROOF DEVICE
(The NASTYTest)
SOLUTIONS OTHERTHAN DEVICES
 ELIMINATETHE CONDITION
 REDESIGN FOR SYMMETRY/ASYMMETRY
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22. Three Strategies for Zero Defects
• Don’t make it unless you need it -- Inventory is a great place
to collect and breed defects
• Make it to withstand any use
• Once you make it, use it right away!
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23. Poka-yoke -- Eight Principles to Improvement
• Build quality into processes -- make it impossible
to turn out defective items even if an error is
committed.
• All inadvertent errors and defects can be
eliminated -- Recognize that mistakes are not
inevitable.
• Stop doing it wrong and start doing it right --
now!
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24. Poka-yoke -- Eight Principles to Improvement
• Don’t think up excuses, think about how to do it right
• A 60% chance of success is good enough -- Don’t wait for the
home run idea, it may never come!
• Mistakes and defects can be reduced to zero when we all work
together to eliminate them
• Ten heads are better than one -- get the “Team” focused on
improvement ideas
• Get to the root cause, using 5W’s and one H -- AskWhy five
times and only then ask How do we fix it?
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25. DO NOT BE
AFRAID, MY
FRIEND
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