This method is not only used by manufacturing or production-type companies. Unknowingly, we encounter poka yoke in our daily lives. The concept of mistake-proofing has become an essential part of product design. Companies now incorporate poka yoke design techniques to ensure end-consumers can use products without incurring mistakes or errors.
Here are some examples of poka yoke in real life:. Incorporating error-prevention and detection within the process helps ensure only quality products are delivered to customers. Other benefits of poka yoke include:. Error-free processes lead to higher levels of quality in products and services. By using poka yoke in your process design, you can strengthen your process efficiency and optimize your production capacity.
Start your journey of self-development with your Personal Kanban , or set up a Portfolio Kanban to visualize your ideal flow of work. Leverage our team of Kanban experts and receive our Kanban email educational series. No credit card. No contract. No risk. What is Poka Yoke? Types of Poka Yoke Poka yoke can be classified into two main categories: Control — Taking physical action to prevent defects or errors from occurring Warning — Sending signals when a defect or error has occurred They can be further classified into three types: Contact, Fixed-value , and Motion-step.
Contact Poka Yoke Contact type poka yoke uses methods to detect physical abnormalities or deformities such as size, shape, color, or weight, to prevent errors. Fixed-value Poka Yoke Fixed-value type poka yoke uses both physical and visual methods to detect whether all components of a part are present and are in the right quantities.
Motion-step Poka Yoke Motion-step poka yoke uses devices and methods that ensure all necessary steps have been taken before a part or product can go to the next step in the process. Poka Yoke Design Examples Poka yoke devices provide fast and effective feedback to alert workers of defects.
Some examples of poka yoke used in manufacturing include: Locator pins Guide pins Proximity switches Alarms Error detection systems Color codes Sensors Checklists Warning signs This method is not only used by manufacturing or production-type companies.
Introduction Shigeo Shingo of Japan invented the concept called Poka Yoke in the s for preventing human errors. Shigeo differentiated the concepts of human mistakes and defects in the manufacturing process. The essential idea of Poka Yoke is to design your process so that chances of mistakes are eliminated at source or at least easily detected and corrected. Prevention type 2. Detection type DOI: Prevention type: In this type of Poka-yoke system, a process is designed so that the defect or mistakes is impossible to occur.
In simple words, prevention Poka-yoke not allowing the possibility for the mistake to occur in the first place. We can prevent the occurrence of human error by: 1.
Elimination 2. Prevention 3. Replacement 4. Facilitation 2. Detection type: In this type of Poka-yoke system, mistakes or errors are easily detected and corrected at the source or next work station. We make sure that mistakes do not turn into defects and reach to customer end. In simple words, detection Poka-yoke allowing the mistake to occur but provide some means of detecting, alerting, and correcting it. We can minimize the effects after occurrence of human by: 1. Detection 2.
Correcting or Mitigating. In manufacturing industries, prevention Poka-yoke generally considered better than the detection Poka-yoke. Control Approach 2. Warning Approach 1. Warning Approach: The warning approach signals the occurrence of defects or mistakes through buzzers, lights, or other warning devices. However, the warning method does not shut down the machine or process 1. Man or Human error 2. Machine 3. Method 4. Material 5.
Measurement 6. Mother Nature or Environment. DOI: Detecting and correcting defects as they occur. The cookie is used to calculate visitor, session, campaign data and keep track of site usage for the site's analytics report. The cookies store information anonymously and assign a randomly generated number to identify unique visitors. The cookie is used to store information of how visitors use a website and helps in creating an analytics report of how the website is doing.
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