Poka-yoke is all around us. The most common example are appliances (washing machines, dryers and microwaves) that come with a mechanism that prevents them from running when the door is open.
Poka-yoke is defined as "mistake-proofing" or "error-proofing." The phrase was originally coined by Shigeo Shingo in the 1960s as part of the Toyota Production System.
Other Examples of Poka-Yoke
- Automatic Spell Check – Keeps us from emailing out common mis-spellings by highlighting the word in red.
- The Lights on your Car's Dashboard – From the traditional low on gas light to the more modern lane departure notice.
- Elevator Door Sensors – To prevent an accident where something is stuck in the door.
Benefits of Implementing Poka-Yoke
- Improved Quality Control: Poka-yoke minimizes human error and ensures that quality control processes are automated. By preventing mistakes, the number of defects and rework is reduced, which directly leads to improved product quality.
- Cost Savings: By catching errors early or preventing them altogether, companies can save on the cost of scrap, rework, and warranty claims. This can significantly reduce the overall cost of production.
- Increased Efficiency: Error-proofing systems help reduce downtime by preventing mistakes that could halt production. When errors do occur, detection systems can quickly identify and fix the problem, ensuring smooth operations.
- Enhanced Safety: Poka-yoke systems can help prevent accidents caused by human error, especially in high-risk industries like manufacturing, healthcare, and construction. By making mistakes detectable and correctable, safety is enhanced for both workers and customers.
- Empowered Workforce: With the implementation of poka-yoke, workers can focus more on value-added tasks instead of worrying about making mistakes. This not only reduces stress but also improves morale and job satisfaction.
Applications Beyond Safety
Poka-yoke is the ideal state for safety. But the concept extends way beyond safety and into convenience. Examples:
- QR Codes
- iPhone facial recognition
- Leak proof water bottles
- Motion Sensor lights
What processes do you have that are Poka-yoke? Send us a photo or shoot us an email at lean@trippnt.com.