What is poka-yoke in lean?

What is poka-yoke in lean?

Poka-Yoke means ‘mistake-proofing’ or more literally – avoiding (yokeru) inadvertent errors (poka). Poka-Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

What is poka-yoke PDF?

Poka-yoke is a concept in total quality management which is related to restricting errors at cradle itself. A poka-yoke is idea generation or mechanism development in a total productive management process that helps operator to avoid (yokeru) mistakes (poka).

What is poka-yoke and examples?

Poka-Yoke’s are mechanisms used to eliminate errors by effectively making it impossible to make mistakes in a given process. And they can be used everywhere. To give an example of Poka Yoke design – filing cabinets could fall over if too many drawers were pulled out at the same time.

How do you process poka-yoke?

5 Steps to Effective Poka-Yoke (Mistake-Proofing)

1. Identify the appropriate type of error detection.
2. Ensure that proper procedures are in place to act when a defect occurs.
3. Implement a system for long-term learning from errors.
4. Continuously develop the system.
5. Get input from the operators themselves.

What are the benefits of poka-yoke?

Applying poka-yoke in your factory can lead to a variety of other benefits, such as:

• Reducing time spent on training.
• Promoting a culture of continuous improvement.
• Improving safety.
• Reducing waste.
• Higher productivity.

What are the types of poka-yoke?

There are two types of poka-yoke: control and warning.

• Control: The goal is to make it mechanically impossible for mistakes to be made.
• Warning: Color or sound is used to alert operators that they are about to make a mistake.

Is poka-yoke a lean tool?

Poka-yoke is a lean manufacturing tool that refers to “mistake-proofing” or “error-proofing” a process. It was originally coined by Shigeo Shingo in the 1960s and implemented at Toyota as part of the Toyota Production System (TPS).

How many types of poka-yoke are there?

There are two types of poka-yoke: control and warning.

Which devices are examples of poka-yoke?

Here are 10 examples of Poka-Yoke in our everyday lives:

• Car safety features.
• Treadmills.
• Microwaves, washing machines, dishwashers, and other household appliances.
• Elevators & garage doors.
• Spell-check functions.
• Leak-proof water bottles & travel mugs.
• Power outlets and USB plugs.
• Overflow outlets in sinks.

What are the 3 levels of mistake proofing?

Mistake Proofing Procedure

• Elimination: eliminating the step that causes the error.
• Replacement: replacing the step with an error-proof one.
• Facilitation: making the correct action far easier than the error.

What is the poka yoke technique?

Poka-yoke is a technique for avoiding simple human error in the workplace. Also known as mistake-proofing, goof-proofing, and fail-safe work methods, poka-yoke is simply a system designed to prevent inadvertent errors made by workers performing a process.

What does poka yoke mean?

Poka-yoke (ポカヨケ, [poka yoke]) is a Japanese term that means “mistake-proofing” or “inadvertent error prevention “. A poka-yoke is any mechanism in any process that helps an equipment operator avoid ( yokeru) mistakes ( poka ). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention…

What is poka yoke system?

Poka-yoke (ポカヨケ, [poka yoke]) is a Japanese term that means “mistake-proofing” or “inadvertent error prevention”. A poka-yoke is any mechanism in any process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.