What is poka yoke?, Classification of poke yoke Poka, What Causes Defects?, Why is it important?, When to use it?, Step by step process in applying poka-yoke, Characteristics of Poka Yoke devices, ADVANTAGES and LIMITATIONS.

1. POKA YOKE
 Presented by:-
Krishna Singh

2. What is poka yoke ?
Poka yoke is mistake
proofing techniques.
Initially BAKA-YOKE
means fool-
proofing.
Changed to POKA-
YOKE means
mistake-proofing. Shigeo Shingo
(1960s)

3. Conti…
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.
Classification of poke yoke Poka
Yoke as Prevention Device:
Poka Yoke as Detection Device:

4. Conti….

5. What Causes Defects?
Errors lead to defects
Poor procedures or standards
Machines
Non-conforming material
Human Mistakes

6. TOUCH SWITCH
Floppy Disk
File cabinets, opening one
drawer locks all the rest
Photoelectric Vibration

7. Why is it important?
Helps people and processes.
Refers to techniques that make it impossible to make
mistakes.
Use the ideas and methods in product and process
design which can eliminate both human and mechanical
errors.

8. When to use it?
It is a technique, a tool that can be applied to any type of
process be it in manufacturing or the service industry.
Poka-yoke can be used wherever something can go
wrong or an error can be made.
Errors can be of any type-
 Processing Error: Process operation missed or not
performed per the SOP.
 Setup Error: Using the wrong tooling or
setting machine adjustments incorrectly.

9. Conti..
Missing Part: Not all parts included in the assembly,
welding, or other processes.
Improper part/item: Wrong part used in the process.
Operations Error: Carrying out an operation incorrectly;
having the incorrect version of the specification.
Measurement Error: Errors in machine adjustment, test
measurement or dimensions of a part coming in from a
supplier.

10. Step by step process in applying
poka-yoke:
Identify the operation or process
Decide the right Poka-yoke approach, such as
Shut out Type: Preventing an error being made.
Attention Type: Highlighting that an error has been made.

11. Characteristics of Poka Yoke
devices
Simple and cheap
Part of the process, permitting 100% inspection
Placed close to where the mistakes occur, providing quick
feedback
Designed to stop a particular mistake
A detection device cannot provide a complete error proof
solution

12. ADVANTAGES
 Remove defect from root cause or source
Faster defect detection and correction
Less attention from worker/operators
Improve safety of workers
Improve equipment effectiveness and assures higher
reliability

13. LIMITATIONS
Requires special expertise in terms of instrumentation
knowledge
Requires work culture of 100% inspection and
perfectionism, which is difficult to sustain
Worker may sometimes fiddle with the instruments,
especially settings on their machines, resulting in losses to
the company

14. THANK
YOU