Poka-yoke (POH-kah YOH-kay) is a Japanese
term for a mistake proofing device (poka=mistake, yoke=prevent).
It was devised by Shigeo Shingo in 1961 and is an enduring and simple
concept. A poka-yoke device can be
for prevention or detection. What are some ways that
poka-yoke can be applied in what we do? Share your ideas.
Characteristics of a good poka-yoke
device:
- simple and cheap
- part of the process
- placed close to the work to provide quick feedback
This is the story
of the first poka-yoke device:
- Problem:
springs were missing from switches.
- Old procedure:
a worker takes two springs out of a box and assembles a switch.
- New procedure:
a small dish is placed in front of the parts box.
The worker takes two springs out of the box and
puts them in the dish. The worker assembles the switch. If
a spring remains in the dish, the worker knows the assembly is missing
a spring.
- Outcome:
the new procedure completely eliminated the problem of the missing
springs.
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