Poka-Yoke is a Japanese term meaning "mistake-proofing" or "fool-proofing" that was first formalized by Shigeo Shingo in 1961 as part of the Toyota Production System. It aims to prevent human errors in manufacturing by identifying potential mistakes, analyzing their root causes, and implementing techniques that make errors impossible by correcting the underlying processes. The benefits of Poka-Yoke include helping processes work right the first time by preventing defects and catching any defects that still occur.

1. Poka-Yoke
By Amit, Hyderabad, India

2. What is Poka-Yoke?
 It is a Japanese term which means
“Mistake-Proofing”
 It was originally known as Baka-Yoke,
which means “Fool-Proofing” / “Idiot-
Proofing”
 It is mostly implemented in Manufacturing
Sectors

3. What is Poka-Yoke?
 It is a Japanese term which means
“Mistake-Proofing”
 It was originally known as Baka-Yoke,
which means “Fool-Proofing” / “Idiot-
Proofing”
 It is mostly implemented in Manufacturing
Sectors

4. History:
 This concept was first formalised and
adopted by Shigeo Shingo in 1961 as part
of the Toyota Production System
 Shigeo Shingo applied this to prevent
human errors
 He recognised the concept of unavoidable
human errors and defects in the
production

5. Why Poka-Yoke?
 For operational excellence
 Can prevent errors from occurring in the
first place
 If this is not possible, it performs a
detective function, eliminating defects in
the process as early as possible
 It ensures that proper conditions exist
before actually executing a process step

6. What is Error?
Error is a deviation from what is Correct,
Right or True.
Previously it was prevented by Scolding,
Retraining or Telling them to be more
careful.
Now it is prevented by Training & Motivation.

7. How to use Poka-Yoke?
 Define the potential mistakes / errors
 List them which could be transferred to the
next step
 Combine them with other tools such as
Brainstorming

8. How to use Poka-Yoke?
 Identify Root Causes
 Investigate and analyze them
 Use other tools such as 5 WHYs for this
step

9. How to use Poka-Yoke?
 Preparation: Completely prepare the
team before they enter into the process
 Encounter: Protect the team who may
misunderstand, ignore or forget their
nature of the job or their role
 Resolution: Remind them of the value of
their input to the continuous improvement
of a service

10. How to use Poka-Yoke?
 Task: Focus on the common mistakes
made while performing the task by the
team
 Treatment: Focus on social interaction
with them
 Tangible: Address the real, physical
impression and experience for the team

11. Benefits of Poka-Yoke
 It helps people and processes work right
the first time
 It is used to create a system that prevents
defects from occurring
 It is used as a system to catch defects
 It refers to techniques that make it
impossible to make mistakes
 Its basic concept is to avoid the problems
by correcting the process