Poka-yoke is a quality assurance technique developed by Japanese manufacturing engineer Shigeo Shingo. The aim of Poka-Yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Poka- yoke has been used most frequently in production environments. Production defects or errors are always the key concerns of any production industry. The success of any organization depends on the quality of product especially right product produced.
Research Inventy : International Journal of Engineering and Scienceresearchinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Research Inventy : International Journal of Engineering and Scienceresearchinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Mistake proofing, or its Japanese equivalent Poka-yoke (pronounced PO-ka yo-KAY), is the use of any automatic device or process that either makes it infeasible for an error to occur or makes the error immediately obvious once it has occurred.
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When you are preserving Human Life... Its all in the Details! Ganbare
Respectfully
Todd McCann
Poka Yoke is a Japanese technique to avoid mistakes before they happen. Include History Overview Examples of mistake proofing and what are the benefits from this system . What is Root cause ,What is 5 Why technique
It’s a quality assurance process introduced by Japanese engineer Shigeo Shingo. This term is used in Japanese language as “Poka” meaning mistake and “Yoke” meaning prevent i.e. mistake preventing or mistake proofing technique.
The purpose of Poka-Yoke is to develop processes to reduce defects by avoiding or correcting (design to show alerts or warning messages to the user) mistakes in early design and development phases.
This Presentation gives a brief idea on what is Poka yoke and the various types of Poka yoke with examples. It also talks about the short comings of Poka yoke
Poka Yoke - Fundamentals by Praneet SurtiPraneet Surti
A presentation on the Introduction, Purpose, History & Origin, Concept, Principles, Methods, Types & Implementation of Poka-Yoke [Mistake Proofing] in any manufacturing or service setting.
Mistake proofing, or its Japanese equivalent Poka-yoke (pronounced PO-ka yo-KAY), is the use of any automatic device or process that either makes it infeasible for an error to occur or makes the error immediately obvious once it has occurred.
Had to Share.
Lock Out Tag Out Poka Yoke Methodology
Details Details Details
When you are preserving Human Life... Its all in the Details! Ganbare
Respectfully
Todd McCann
Poka Yoke is a Japanese technique to avoid mistakes before they happen. Include History Overview Examples of mistake proofing and what are the benefits from this system . What is Root cause ,What is 5 Why technique
It’s a quality assurance process introduced by Japanese engineer Shigeo Shingo. This term is used in Japanese language as “Poka” meaning mistake and “Yoke” meaning prevent i.e. mistake preventing or mistake proofing technique.
The purpose of Poka-Yoke is to develop processes to reduce defects by avoiding or correcting (design to show alerts or warning messages to the user) mistakes in early design and development phases.
This Presentation gives a brief idea on what is Poka yoke and the various types of Poka yoke with examples. It also talks about the short comings of Poka yoke
Poka Yoke - Fundamentals by Praneet SurtiPraneet Surti
A presentation on the Introduction, Purpose, History & Origin, Concept, Principles, Methods, Types & Implementation of Poka-Yoke [Mistake Proofing] in any manufacturing or service setting.
Learn What is Poka Yoke, Elements of Error Proofing, General Inspection, Error Proofing Devices, Ways to Mistake Proofing, Common Sources of Errors, Poka Yoke Principle and much more.
POKA-YOKE - A Lean Strategy to Mistake ProofingTimothy Wooi
A Lean Strategy in Human Error Prevention aims to detect and correct possible error immediately, eliminating defects at the source.
Poka-Yoke overcome the inefficiencies of inspection through the use of automatic devices that seek,
1.Not to accept a defect for the process
2.Not to Create a Defect
3.Not to Allow a Defect to be passed to the next process
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
The concept was formalized, and the term adopted, by Shigeo Shingo as part of the
Toyota Production System.
It was originally described as baka-yoke, meaning "fool-proofing“ or “idiot proofing” but the name was later changed to the milder poka-yoke.
Implementation of Poka Yoke and Safety Push Button in Rubber Grommet and Slee...ijtsrd
Poka yoke is a technique that is used for avoiding human error in the workplace. It is also known mistake proof method and fails safety working methods poka yoke is a system it is designed to prevent errors or mistakes made by the operator performing work or process. Today, this concept is used in current industries production system helped design, averages poka yoke devices per machine in their manufacturing plants, thus validating the concept as beneficial to the industry in this article is used to reducing rejection and customer complaints, detect wrong punching bracket holes and only finish good material is supplied customer reduced wrong assembly bracket. An examination in Precision list the potential benefits as Sachin Ahirrao "Implementation of Poka-Yoke and Safety Push-Button in Rubber Grommet and Sleeve Assembly Bracket Machine" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-6 , October 2020, URL: https://www.ijtsrd.com/papers/ijtsrd33566.pdf Paper Url: https://www.ijtsrd.com/engineering/mechanical-engineering/33566/implementation-of-pokayoke-and-safety-pushbutton-in-rubber-grommet-and-sleeve-assembly-bracket-machine/sachin-ahirrao
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.
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Jidoka, a fundamental pillar of Lean manufacturing and the Toyota Production System (TPS), is a concept that revolutionizes how we approach quality control in manufacturing. Derived from Japanese, "Jidoka" translates to "automation with a human touch." It represents a powerful strategy for building quality into the production process, thereby enhancing product quality, reducing waste, and fostering more efficient and reliable manufacturing practices.
What is Jidoka?
Jidoka is a manufacturing philosophy that seamlessly blends automation and human intervention. It encompasses the automatic detection of problems (automation) and empowers humans to intervene when necessary (autonomy).
Benefits to Practitioners of Lean Manufacturing:
1. Improved Product Quality: Jidoka's focus on early defect detection ensures that faulty products are identified and addressed promptly, preventing the production of defective goods.
2. Reduced Waste: By catching defects early in the production process, Jidoka minimizes rework, scrap, and the consumption of additional resources, contributing to waste reduction.
3. Enhanced Efficiency: Jidoka optimizes processes by prioritizing quality over quantity, leading to more streamlined and reliable manufacturing operations.
4. Empowerment of Workers: Jidoka empowers frontline workers by enabling them to take immediate action when issues arise, promoting a culture of continuous improvement.
The Four Steps of Jidoka:
Jidoka consists of four essential steps, each contributing to its overarching goal of enhancing quality and efficiency:
1. Detect the Abnormality:
- Goal: Identify deviations from the standard process.
- Key Activities: Implement Poka-yoke devices, use time as a detection mechanism, and employ visual controls like andon and Kanban for immediate problem signaling.
2. Stop Production:
- Goal: Halt production immediately upon detecting an abnormality.
- Key Activities: Initiate manual or automatic stoppage of the process to prevent the production of defective goods.
3. Fix the Problem at the Source:
- Goal: Address the root cause of the issue and ensure production can resume smoothly.
- Key Activities: Fix or correct the abnormal condition, implement temporary countermeasures, and make decisions at the lowest possible organizational level.
4. Implement Countermeasures:
- Goal: Prevent the recurrence of the abnormality and foster continuous improvement.
- Key Activities: Investigate the root cause of the problem, install permanent countermeasures, and prioritize efforts for ongoing process enhancement.
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Chinese factory managers often say things such as “these three people caused this issue”, “it is their fault”, and “these are human mistakes and they can’t be avoided”. However, one could argue that the factory’s systems are at fault. And who can develop and implement systems? The managers themselves, not their employees.
Which systems need to be put in place to avoid mistakes and improve product quality? Let’s look into 7 mistake proofing approaches that work...
The purpose of this study is to analyze empirically by using secondary data on the possibility of corporate fraud by using various fraud theory approach. The research model in this study was tested using the ordinary least square (OLS) analysis method. A total of 310 company data were collected which consisted of financial data and other supporting data published by companies listed on the Indonesia Stock Exchange in the range of 2012 to 2017. This study provides empirical evidence that all the variant of fraud theory (fraud triangle theory, fraud diamond theory and fraud pentagon theory) can be investigated for its significant effect on corporate fraud by only using secondary data that are available and freely accessed by the public. The empirically tested research model in this study can provide a comprehensive understanding of practitioners, academics, government agencies and the general public in analyzing the topic of corporate fraud.
Traditional markets in Indonesia were created so that people from all walks of life can fulfill their needs, especially staple food products, without having to spend a lot of money. However, the prices of food products in different markets vary depending on the consumers of the particular market. The aims of this article were to compare the price difference of staple food products in several traditional markets and to find out the factors that cause the price difference. The data were collected by carrying out a survey to five traditional markets around Jakarta regarding the prices of ten staple food products. The data were analyzed quantitatively using statistical calculation ANOVA from SPSS version 22, and also qualitatively to discuss several factors underlying the price differences. Results revealed that price differences of staple food products were not only caused by market location, but other factors such as pricing strategy and consumer specification. This research implied that traditional markets were still chosen by Indonesian consumers to fulfill their needs because of the competitive price.
Airport enterprise innovation performance is a crucial issue that planners, decision makers and managers should focus in order to drive the airport enterprise performance towards sustainable development. The strategic infrastructure needs, and investments need to include improvements across all major factors that affect the innovation dimension of sustainable development.
Key objective of the paper is to highlight the challenges in airport enterprise management towards sustainable development in terms of innovation improvement. A performance evaluation towards innovation and sustainable development framework is adopted and a case study application highlights the crucial role of airport enterprise management performance innovation dimension towards sustainable development. Conventional wisdom is to stimulate the interest on topic and promote a framework addressing to evaluate airport enterprise management performance towards innovation and sustainable development.
In the business world, companies need high performance. Performance is the result or overall success rate of a person over a period of time in carrying out tasks compared to various possibilities, such as predetermined standards of work, targets, or criteria. The purpose of the study was to analyze the influence of intellectual intelligence, emotional intelligence, and spiritual intelligence on employee performance. The population in this study were 63 employees of PT PLN (Persero). This study uses quantitative associative, with data analysis used is multiple linear regression analysis. The results showed that both intellectual intelligence, emotional intelligence, and spiritual intelligence had a positive and significant effect on employee performance. Intellectual intelligence has the greatest influence on employee performance, followed by spiritual intelligence and emotional intelligence. Intellectual intelligence, emotional intelligence and spiritual intelligence together have an effect of 52.4% on employee performance, and the remaining 47.6% is influenced by other factors not explained in this study.
The main purpose of the research study is to analyze the effect of organizational commitment, job satisfaction and work insecurity as well as their impact on the performance of Bank Aceh Syariah. The samples of the research are 209 employees which are selected with survey methods. Data was collected by using questionnaire, and then the data was analyzed with statistical methods of structural equation model (SEM). The study found that the organizational commitment and job satisfaction have a negative effect on turnover intention, but positive effect on the performance of Bank Aceh Syariah. The work insecurity has a positive effect on turnover intention, but negatif effect on the performance of the bank.
This study aims to test the effect of employee engagement and organization trust on organization citizenship behaviour and its impact on organization Effectiveness. The object of this research is the government organization of Pidie Jaya with Echelon IV Officers as a respondent. The number of sample is determined by using proportional sampling technique and Slovin equation, and it provides 171 respondents. Data is analyzed using the path analysis with the SPSS program assistance. The findings describes that employee engagement, organization trust, organization citizenship behaviour and organization Effectiveness have been going well. For the verification test of direct effect provides: employee engagement effects organization citizenship behaviour; organization trust effects organization citizenship behaviour significantly; employee engagement effects organization Effectiveness significantly; organization trust effects organization effectiveness significantly, and; organization citizenship behaviour effects organization Effectiveness significantly. These all findings prove that the previous theories are still applicable, and these also apply in Government organization of Pidie Jaya District. The originality of this research is in its novelty in term of the object, time, and statistic approach. This result contributes to academic and research area in order to develop the next model and method. For the practical, this has verified that the variables in this research need more attention from the managers especially in organization related.
This paper is an analysis on the impact machine learning, Artificial Intelligence, and robotics has on the supply chain management. The analysis covers the basis of AI in the SCM mechanisms while defining it from the ground up. Later on, to shed a true light on supply first the paper zooms in on the effects of machines in marketing. From what particular methodologies are deployed in today’s environment extending all the way to its anticipated outcomes. As the reader progresses he/she will find valuable studies on the main segments of machine learning within the supply chain itself. Certain novelties and innovations are scrutinized regarding SCM alongside these studies. These innovations are exemplified by certain cases presented in Part 3. The penultimate section briefly examines the possible drawbacks of the surge in machine application in SCM. The final section compiles the ideas presented in the paper as a whole and gives a glimpse of an estimate for the near future.
Huang (2018) decomposes the differences in quantile portfolio returns using distribution regression. The main issue of using distribution regression is that the decomposition results are path dependent. In this paper, we are able to obtain path independent decomposition results by combining the Oaxaca-Blinder decomposition and the recentered influence function regression method. We show that aggregate composition effects are all positive across quantiles and the market factor is the most significant factor which has detailed composition effect monotonically decreasing with quantiles. The main decomposition results are consistent with Huang (2018)
In Kenya, the newly promulgated constitution of 2010 (CoK, 2010), provides the basis of monitoring and evaluation as an important tool for operationalizing National and County Government projects to ensure projects success, integrity, transparency and accountability. The county governments are responsible for delivering basic services in collaboration with other agencies and partners to enhance quality of life: however, the county government projects has been marred by lack of integrity, transparency, accountability and litany of other monitoring and evaluation weakness which has undermined the impacts and success of projects including Regional Economic Blocs. Lake Region Economic Bloc (LREB) which comprised of fourteen counties bordering Lake Victoria Basin is not sparred either. The study was conducted in six LREB Counties namely, Migori, Homabay, Kisumu, Siaya, Kakamega and Vihiga chosen in a random manner. This study specifically assessed the effectiveness of Monitoring and Evaluation methods on the Performance of County Governments Projects. The study was guided by the theory of change. The research was carried out using descriptive survey design which entails both qualitative and quantitative data collection procedures. The researcher used stratified random sampling techniques to draw a sample from the study population. The qualitative method focused on group discussion and in-depth interviews. The quantitative techniques employed questionnaires to 398 purposively selected subjects from the county projects. Data collection was from two main sources; primary and secondary. Secondary sources included relevant county documents, constitution, legislations, policy documents and reports among others. The Study employed questionnaires, Focus group discussion and Interview guide as its primary data collection method. Statistical Package for Social Science (SPSS) version 18.0 was used for analysis. Data was analyzed using descriptive and inferential statistics techniques and presented in tables and figures. The study findings indicated thatM&E methods, indicated by the coefficient of effectiveness (R2) which is also evidenced by F change 109.403>p-values (0.05). This implies that this variableis significant (since the p values<0.05) and therefore should be considered as part of effectiveness of M&E systems on the performance of County Governments projects. The study concludes that there are no effective and adequate projects monitoring and evaluation methods in place for County Government Projects, which can facilitate the achievement of desired projects performance and outcomes. The study recommends that the County Government should develop a clear M&E methods for each project with clear data collection, analysis, reporting and implementation methods. This Study recommends further research to be conducted in the other Regional County Economic Blocs.
Regardless of where the Igbo man is, within or without the Igbo regions, trust is one of the foremost vital tool in business dealings and negotiations. This study aims at revealing the kind of trust apparent, and unique to the Igbo-men in business, how the Igbo-men build trust in their business, the antecedents of trust building in Igbo land, and the impacts of those trust in business dealings and negotiation. Through the process of content data analysis, results were drawn from a percentage margin of answers and feedbacks generated from real life experiences and discussions from unstructured interview from selected Igbo-men across the five states of the south-east region of Nigeria, which shows that 70% percentage of the Igbos practice the affective based trust in business dealings and negotiations, while 18% percentage practice cognitive based trust, 7% engages in both affective and cognitive based trust, and the remaining 5% are undecided.
This study is directed to determine the role of government treasurer in state university in tax compliance. With the spirit of the state apparatus, especially the Civil Servant, in reporting the taxes, it is expected to become a continuously growing and infectious snowball to the taxpayers to report their taxes correctly, completely and clearly as well as to avoid administrative sanctions that are subject to such non-compliance. This study method used is qualitative, the source of this study is government treasurer. The use of this qualitative approach is based on the concept of natural setting, grounded theory, descriptive, more concerned with the process than the outcome, temporary design, and research results are negotiated and agreed upon. The results show that treasurers have a big role in tax compliance, but however, there are still many obstacles that must be faced in fulfilling their financial obligations. this research was conducted only in one state university, so that data that could be processed was very limited.
The corporate governance is a popular topic within two last decade, and the emerging economies are practicing &enhancing their performances. The review is conducted to assess the effectiveness of the corporate governance implications on firm’s performances. The study followed the deductive approach and the journal articles, and the reports have used the source of the review. As per the literature findings, the researcher developed a conceptual design for the case review. The independent variable is the corporate governance mechanism, and the dependent variable is organizations performances. Both independent and dependent variables comprise the different type of corporate governance practice and the different function of the organizational performances. The review found that all the types of corporate governance practices are influenced to the organizational performance and the better corporate governance mechanism can enhance all type of performances.
Innovative work behavior is likely to be an important need for the increasing performance of the hospital to provide the health public services. Theoretically and empirically, the behaviors be related to employee perception on management support, information technology and employee empowerment. The study aims to determine the effect of management supports and information technology on employee empowerment as well as their impact on the innovative work behaviors of the employee of dr. Zainoel Abidin District Hospital Banda Aceh. The study conducted of 302 employees of the hospital. The data collected by questionnaire and then the data is analyzed by statistical means of structural equation model (SEM). The study found that management support and information technology have a positive and significant effect on the employee empowerment and innovative work behavior. The employee empowerment mediates the effect of management supports and information technology on the innovative work behavior.
This research deals with an insight and analysis of the economy projectification in a smaller country, here represented by Croatia. The study was inspired by similar research conducted in Germany, Island and Norway and it is based on similar but partly adapted methodology. The objective of this study is to measure level of economy projectification in a smaller country, and to provide relevant data related for the level of project work. The random sample of 250 companies, from both public and private sectors, was selected across nine sectors of the economy. A stratified random sampling was drawn and interviews were conducted via telephone, so as on-line survey. While analysing collected data and considering the objectives of this paper, only basic statistical analyses were applied for calculating averages and mean values. This study confirmed that projectification trends and figures in a smaller country are similar to those in larger or developed countries. During the period of last five years, the projectification level of the Croatian economy was increased from 27% (in 2013.) to33% (in 2018.). The results show significant difference in projectification among the different sectors of economy, so as changes and trends over the recent time period.
This paper is designed to show how integrated process planning and cross employee planning can be a vital part to any business operation. It will also uncover how different integrated processes and employee relations will help a business to grow. Various topics ranging from enterprise resource planning, integrated planning in supply chains, the non-linear approach, innovation and digitalization coupled with cross training and empowerment, Human resources, and Manager Employee relations complement each other and could bring an organization together. Various thought processes and intellectual reasoning skills were instrumental in all consideration of this project. Many antiquated processes were changed over the years to update operations in the business world where conventional means were not effective. Integrating product planning and employee planning optimized operations both in the product and service industry and I will accent many of these optimizations. With recent technological advances and human relations tactics, project management and organization has been streamlined and works more productively than its predecessors. Regardless of the industry, integrated process planning, and cross employee planning could possible turn a dinosaur into a competitive part of the economy.
One of the problems in big cities are transportation.They solve this problem by providing mass transportation such bus or train. People use this facility to travel between surrounding cities or within the city. Jakarta recently has a new public transportation called TransJakarta which serving people travelingfrom nearby cities and in the city.In order to move or doing business between places people in Jakarta use TransJakarta This research aims to analyse ticket price, service quality and customer value toward customer satisfaction. We conducted a research by using questionnaires given to thepassangers and developed a model using a multiple regression to process the result from questionnaires. Samples were taken from The number of sample for this reseach was 130 customers taken from one bus stop which passengers traveled from BSD City to Grogol and Slipi. The results from partial testing showed that customer value andservice quality have effect on customer satisfaction while ticket price does not have effect on customer satisfaction.
This study aims to examine the mediating effect of Trust in the relationship between Perceived Website Quality (PWQual), eWOM, and Perceived Benefits on Consumer Attitudes Toward Online Shopping in Indonesia. The sample in this research are online shopping consumers in Indonesia there 118 respondents. The design research used a survey model purposive sampling method as a sampling technique. The data analyze in this research used Structural Equation Modeling (SEM) as an analysis technique with AMOS as analysis tools. This research shows that : Perceived Website Quality has a significant effect on Perceived Benefits and Trust, Perceived Benefits and Trust has a significant effect on Consumer Attitudes Toward Online Shopping, Perceived Website Quality has a significant effect on Consumer Attitudes Toward Online Shopping through Trust
Dairying is one of the livestock productions practiced almost all over Ethiopia, involving a vast number of small, medium, or large-sized, subsistence or market-oriented farms. However, the structure and performance of dairy sectors and its products marketing both for domestic consumption and for export is generally perceived poor in Ethiopia due to different challenges. These challenges vary across different production system to another and/or from one location to another. Among other challenges seasonality of production, spoilage (lack of milk collecting facilities), poor animal health and management, inadequate supply of quality feed, low productivity and genetics ,quality problem, weak vertical integration, absence processing plant, inadequate permanent trade routes and other facilities like feeds, water, holding grounds, lack or non-provision of transport, lack of access to land, ineffectiveness and inadequate infrastructural and institutional set-ups, prevalence of diseases, lack of credit and inadequate market information are dominant in Ethiopia. Therefore, market infrastructure facilities, producers cooperative, feed quality and quantity provision system need to be strengthen for effective dairy value chain development.
This research paper examines customer intention to reorder in respect to delivery service and product satisfaction. Our research model includes delivery service, satisfaction and reorder intention. Satisfaction in this research model work as mediating variable. A survey method was adopted to collect data, collected data were analysis using SPSS to see the correlation between variables. A significant relationship was found between delivery service and reorder intention as well as moderating role was also note with satisfaction and reorder intention.
This paper examines the impact of internet use on student performance. In this cross-sectional study, one hundred twenty survey responses were collected from plus two-level students from BirendranagarSurkhet. The respondents were selected from class 11 and 12 students randomly. Frequency of internet use, location of internet use, cooperation from teachers for internet learning and peer group influence on internet use for academic purpose has been analyzed with their academic performance.one sample t test was used to analyze the data. The finding concludes all these variables have positive impact if the student use internet for learning process. Similarly, the analysis shows that the student who used internet at home for learning purpose has found highest academic achievement.
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Sustainability has become an increasingly critical topic as the world recognizes the need to protect our planet and its resources for future generations. Sustainability means meeting our current needs without compromising the ability of future generations to meet theirs. It involves long-term planning and consideration of the consequences of our actions. The goal is to create strategies that ensure the long-term viability of People, Planet, and Profit.
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Poka–Yoke – solution to human errors in the production process
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The International Journal of Business Management and Technology, Volume 2 Issue 5 September-October 2018
ISSN: 2581-3889
Research Article Open Access
Poka–Yoke – solution to human errors in the production
process
*Peter Malega
*Technical university of Kosice, Faculty of Mechanical Engineering, Institute management, industrial and digital
engineering, Park Komenskeho 9, 04 200 Kosice, Slovak republic, peter.malega@tuke.sk
Abstract
Poka-yoke is a quality assurance technique developed by Japanese manufacturing engineer Shigeo Shingo. The aim of
Poka-Yoke is to eliminate defects in a product by preventing or correcting mistakes as early as possible. Poka- yoke has
been used most frequently in production environments. Production defects or errors are always the key concerns of any
production industry. The success of any organization depends on the quality of product especially right product
produced.
Keywords: error, method, production process, POKA-YOKE
I. INTRODUCTION
Poka – Yoke is a quality management concept developed by a Matsushita manufacturing engineer named Shigeo Shingo
to prevent human errors from occurring in the production line. Poka – Yoke (pronounced “poh-kahyoh-kay”) comes
from two Japanese words – “yokeru” which means “to avoid”, and “poka” which means “inadvertent errors.” Thus,
Poka – Yoke more or less translates to “avoiding inadvertent errors”.
The main objective of Poka – Yoke is to achieve zero defects. In fact, it is just one of the many components of Shingo‟s
Zero Quality Control system, the goal of which is to eliminate defective products.
II. POKA – YOKE IN GENERAL
Increasing emphasis on the quality of performance in each area of production characterizesthe present work
environment. Organizations focus on improving existing quality management system, quality tools and methods.
However, on the human and his activity in the production process must also focuses attention. This stance views people
as inseparable part of production. It is natural for a human being to make mistakes. People are not able to repeat
hundreds times the same operation without any differences. In Fig. 1 below, we can see the most common errors that
occur in the production process.
Fig. 1 Most frequent errors in the production process 1
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Poka–Yoke – solution to human errors in the production process
Previous methods of addressing human errors in the production process involved counselling workers and insist them
to be more careful. Today´s methods exist to help workers avoid mistakes by using a wide range of actions and devices.
These methods prevent workers from committing and repeating errors. Fig. 2 highlights principles of these methods and
their fundamental differences.
Fig. 2 Defect detection and prevention strategies 1
The first method illustrate is The Successive check. It demonstrates that improvements occur more rapidly when quality
feedback is timely. The key element of Successive check is frequent inspections. The focus of this method is for the
nearest downstream operation to check the work of the prior operation in terms of production and quality inspection.
The Self – check method is based on control of individual operator work. This provides even faster feedback than
Successive check. Since the worker checks each unit produced, he can recognize changes in conditions and detect error.
Self – check is preferred to Successive – check whenever possible.
Both, Successive – check and self – check provide information after defects occur. The Poka – Yoke method instead of
emphasizing the detection of errors focuses on preventing. 1, 2
III. THE CORE PURPOSE OF POKA – YOKE
Shingeo Shingo in Toyota Motor Corporation introduced the Concept of Poka – Yoke in 1961. Its original term Baka –
Yoke represented Fool – Proofing. In 1963, this term was change to Poka – Yoke that means Mistake – Proofing, because
of connotative associations inherent in the previous title.
Poka – Yoke is based on 5 basic principles. Table 1 enumerates these principles as well as their descriptions.
Table 1. Basic principles of Poka – Yoke 2
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Poka–Yoke – solution to human errors in the production process
This concept is used in processes, which are known as lean manufacture processes. Poka – Yoke is one element of Zero
Quality Control. Its aim is to achieve zero defects and eliminate or reduce control of quality. Poka – Yoke ensures the
existence of proper conditions before performing even the first step of a process. “The Purpose of Poka – Yoke is to
eliminate defects by preventing, correcting or drawing attention to human errors as they occur.” A technique makes it
impossible to commit errors. Due to the implementation of fail-safe tools, operators cannot select a wrong part or leave
part out. Poka – Yoke encourages production without defects and increases of reliability. This method can be applied to
entire processes such as production, sales and purchasing. 3, 4
IV. PRINCIPAL FORMS OF POKA – YOKE
As was previously mention in general there exist two different ways of implementing Poka – Yoke in the production
process. Poka – Yoke can take prevention or detection forms, as illustrates Fig. 3.
Fig. 3 Major categories of Poka – Yoke 5
The Prevention form of Poka – Yoke ensures that a defect is not going to reoccur throughout the entire process. Suppose
an abnormality is about to happen. Prevention based Poka – Yoke provides two approaches, control and warning.
The Control approach halts the process immediately after detection of defects in a product so corrective action can be
performed. The result is to keeping a suspect part in place when an operation is incomplete. Serial defect generation is
prevented. The Control approach does not depend on assembler. A practical example of the Control method is when a
component missing a part. The process will pause if the component is discovered before the next assembly step.
The Warning approach aims to attract the attention of an operator when a mistake is occurring. The operator should
stop the process and correct the problem. Unlike the Control approach, a disadvantage of the Warning approach is that
an operator can miss the signal and continue to process the defective product. Warning approach depends on assembler.
With the warning method, it is typical to use signal devices such as buzzers, lights and other warning kinds of devices.
This approach is cheaper but also less effective in comparison with the Control approach. 5, 6
Stilly the total prevention of defects may not be feasible in real conditions. One of the reasons is the economy of Poka –
Yoke measures and considers production costs. The Detection form of Poka – Yoke focuses on cases where mistakes
have been made. The Detection form distinguishes three categories, Contact method, Fixed value method and The
Motion step method.
The Contact method identifies product defects by testing the product's shape, size, colour or other physical attributes.
Testing is realized through mechanisms that are kept in direct contact with a particular part. The Contact method also
includes a subset category, The Non – contact method. This method works on the basis of photoelectric cells.
The Fixed – value method uses physical and visual methods to ensure that all components are available in the right
quantities. This method tends to be used in operations in which a set of steps are sequentially performed. Typical
mechanisms used by The Fixed – value method are automatic counters and optical devices built into progressive
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Poka–Yoke – solution to human errors in the production process
stamping, welding and automatic insertion equipment. This method can be combined with The Contact method for
better detection.
The Motion step method ensures that the correct number of steps will be taken and the correct sequence of steps. In
other words, that a step that is not part of the normal process cannot be mistakenly performed. 5, 6, 7
After determination of the purpose and core forms of Poka – Yoke arises the question of the implementation of this
system through the whole organization.
V. IMPLEMENTATION PHASE OF POKA – YOKE
The initial implementation of Poka - Yoke should forego the phase of the identification of possible errors and how they
occur in the design stage. It is important to identify The Poka –Yoke opportunities that will have the biggest impact on
the customer and yield the best return on investment. One way is through the failure mode effects analysis (FMEA).
After that, Poka – Yoke can be implemented at any step of the manufacturing process where it was found that an error
could be made.
An unnecessary condition for the implementation of Poka – Yoke management is where a strong foundation exists in
total quality management. There are five other conditions for effective implementation of Poka – Yoke 8:
1. Organization has to be strongly customer focused.
2. Organization must promote quality ownership at the source.
3. There must be a clear distinction between good versus bad quality.
4. Organization must adopt a PSP philosophy, meaning Pre-, Self-, Post- Inspection at the source.
5. Real – time feedback and corrective action are required.
The implementation of Poka – Yoke can proceed on three different levels. At the physical level, focus is on the
elimination of conditions that may lead to errors by installing components. The operational level includes installing
devices to fortify correct assembly processes. Philosophical level deals with identifying the causes of errors and their
disposal.
Applying the process of Poka – Yoke consists of six steps 9:
1. Poka – Yoke should mainly focus on the most valuable process for organizations based on The Pareto principle.
2. Identify five possible reasons for failure of the process and understand them.
3. Choose application form of Poka – yoke in the organization. As it was mentioned and described, distinguish
the two basic forms, the prevention and detection form of Poka – Yoke.
4. Choose a particular method of the selected form such as contact method or control method etc.
5. Test the method and observe the results.
6. Train the operator of production and evaluate performance.
Poka – Yoke is implemented by using simple objects and devices such as fixtures, jigs, and warning devices. These
devices should have the following features 8:
They should be characterized by exceptional suitability for eliminating defects.
They should be simple and cheap leading to cost effectiveness.
They have to be part of the inspection process.
They need to be placed close to where mistakes occur for effective feedback and instantaneous corrective
action.
They need to be capable of being used all the time by all operators.
Poka – Yoke uses physical contact devices, energy sensing devices and warning sensors. Each of these categories
includes a wide range of devices that can be used depending on the process.
The next Fig. 4 represents the most common devices.
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Poka–Yoke – solution to human errors in the production process
Fig. 4 The most commonly used physical contact sensors, energy sensors and warning sensors9
Besides manufacturing industries Poka – Yoke is used also in service based - organizations. In both areas, the customers
are the mainstay. The difference in implementation is that manufacturing typically only considers errors made by the
operator. Because service organization interface in many ways to transfer a service to the customer, they must consider
errors from server and customers. Due to this consideration, Poka – Yoke distinguishes between Server Poka – Yoke and
Customer Poka – Yoke.
Server Poka – Yoke errors can be classified as errors in task, treatment and tangible aspects of service (see Fig. 5). These
three areas are critical because they explicitly relate fail – saving actions to specific dimension of service.
Fig. 5 Server Poka – Yoke 10
Task Poka – Yoke concentrates on common sever errors, which may occur during performance of the task for the
customer. This may include doing work incorrectly, not requested or in the wrong order.
Treatment Poka – Yoke focuses on the social interactions between customer and server such as greeting and eye contact.
Particular examples of this type include failure to acknowledge the customer, listen to the customer or reacting
appropriately to the customer. The aim is to ensure that customers receive proper, fair and consistent treatment.
Tangible Poka – Yoke involves connecting with physical elements of service such as clean facilities and proofread
documents for content. Additionally, it is the direct task of the server in this area to improve the tangible, physical
impression and experience of the customer. 11, 12
Customer Poka – Yoke errors are commonly composed of errors in preparation for encounter, the encounter and the
resolution of the encounter (Fig. 6). The customer has an integral role in the service. Their actions need to be fail – safe at
each stage of service to ensure that service works as was designed.
Preparation Poka – Yoke struggles with full preparation of a customer before entrance to the service. Possible errors
may relate to bringing necessary materials to the encounter, understanding and anticipating the role of the customer in
the service transaction and engaging the correct service.
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Poka–Yoke – solution to human errors in the production process
Encounter Poka – Yoke attempts to solve customer errors during the encounter, which can be due to inattention,
misunderstanding or memory lapse.
Resolution Poka – Yoke reminds the customer of the value of their input for the continuous improvement of a service.
Customers should evaluate their experiences and provide feedback to the service provider. Problems can also appear in
areas such as signal service failure or the execution of appropriate post – encounter actions.
Fig. 6 Customer Poka – Yoke 11
VI. POKA – YOKE AND SOFTWARE APPLICATIONS
Poka – Yoke is not just a manufacturing technique. It is rarely mentioned in terms of software use. However, software in
the present time is coming more and more to the fore. Therefore, it is important to find application possibilities for Poka
– Yoke in this area.
In both, manufacturing processes and software use, Poka – Yoke can has prevention or detection forms. Prevention
forms are represented in the development of computer languages. One object of this language is to prevent creating
codes that are prone to errors. Software testing is a detection form of Poka – Yoke. Programs such as Lint (tools that flag
suspicious usage in software) can do this testing. These tools examine the syntax of programs and alert the programmer
of possible mistakes.
CONCLUSION
Quality costs are a significant part of total cost. Continued effort to decrease quality cost brings significant competitive
advantage. Quality costs originate in many cases from human error. Poka – Yoke is concerned about understanding and
solving human mistakes in production. It analyses the process of knowing where mistakes occur and the root causes
them utilizing a range of approaches and devices. Poka – Yoke represents an excellent method for the elimination of
human errors in the production process and thereby reducing costs in production.
Acknowledgements
This article was created by implementation of the grant project 029TUKE-4/2016 Education and Training Centre of Innovation
Development and Implementation of business processes and systems.
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