Poka-yoke is a Japanese term that means "mistake-proofing" and refers to mechanisms in manufacturing processes that help operators avoid errors. Its purpose is to eliminate defects by preventing, correcting, or drawing attention to human mistakes. Poka-yoke was developed by Shigeo Shingo at Toyota to achieve "zero defects" through fail-safe mechanisms. Examples include lifts that prevent overloading and include alarms if weight limits are exceeded. Implementing poka-yoke helps improve quality, productivity, and efficiency by reducing errors, rework, and waste in manufacturing processes.

1. Toyota 1st car

2. History
The term poka-yoke was applied by Shigeo
Shingo’s in the 1960s
1919 to 1991

3. Poka-yoke is a Japanese word that means
"fail-safing" or "mistake-proofing".
A poka-yoke is any mechanism in a lean
manufacturing process that helps an
equipment operator avoid mistakes .
Its purpose is to eliminate product
defects by preventing, correcting, or
drawing attention to human errors as
they occur.

4. Poka-Yoke was developed by Shigeo Shingo from Toyota
Motor as a tool to achieve Zero Defects.
• The process of Zero Defects is also
known as “Mistake Proofing” or “Fail-Safe”.

5. Old type’s Lift
Set by engineer in a
building
&
Its maximum weight
capacity is 200 kg

6. Weight
50kg
Weight
60 kg
Weight
90 kg
Lift capacity=People weight

7. Total lift
capacity =200

8. If more people
enter the lift then
weight will
increase, which
increases the
possibility of
break down of
lifts wire because
there is no
warning
mechanism on
excess weight .

9. Latest lifts are very
advanced, because
when it is over weight
the alarm will start &
indicate light , until
weight is not reduced
This is done through
poka yoke

10. Lift move
without
any
fault.

11. Here
people want lift but he /she
can’t use , why ?
Because lift can’t run on
overload. People want but
they can’t use. This is good
for our safety, so here no any
defect comes out .
This is also called zero
defect.

12. Key principle

13. Error is inevitable but can be eliminated

14. Before Poka yoke After Poka yoke

15. Where I
put my
keyboard
cable
???

16. To achieve quality, it has to be
designed into the product

17. If I want to build good quality
product we should use good
quality material.

18. Mistake provides an opportunity
for improvement and errorAAA,
Next time
I will not
do

19. Mishaps/error/problem/crisis are the results of
inadvertent negligence of small little things(small
things) by some one in the chain.

20. Cent percent inception deployed at the end-of-the line
cannot solve the problem of defects

21. Cent percent inception cannot
ensure 100 percent quality

22. The faster we discover the problem, the
easier and less expensive it is to correct it.

23. Characteristics of poka yoke

24. Fail safe machine for
quality control
Poka yoke
proofing is
powerful because
its every part is
connected to a
digital signal so
when any fault is
found signal is
passed
simpleinexpensive
comprehensive

25. Advantage of poka- yoke

26. Element rejection and rework.

27. Reduce transport, handling,
and rerouting of job.

28. Let’s take a
tea break
where I am
at fault?
Free a person’s mind from
maintaining repetitive vigil.

29. Build
up
moral
on the
floor

30. Creates extra capacity which is
otherwise wasted due to rework
and rejection

31. Improve productivity of the
process