Poka-Yoka Exercises

There are three different situations below where Poka-Yoka can be applied. Each team will be assigned one of the problems. Directions Get together as a team and review your problem. Brainstorm for ideas on Poka-Yoka applications that will prevent the error from ever occurring. While you only have to come up with one idea, it would be desirable for your team to come up with several. Remember the idea is to make the solution as simple and cost effective as possible. Do not fundamentally change the product, or look for solutions that will require large outlays of capital to implement. You will have 15-20 minutes to come up with your ideas. Select a spokesperson that will share your Poka-Yoka applications with the class. (Use a flip chart to visually show your ideas) Have fun and be creative!

Situation 1
A radio manufacture in China has discovered a problem. A voltage warning sticker is often being placed upside down because it is written in English. The workers in the plant do not speak English. What Poka-Yoka applications could solve this problem?

Situation 2
A maker of motherboards for a computer has a process that requires an operator to drill six holes in the board, so that it can be attached to the computer case. There are times when the operators have failed to drill all six holes, which has caused a significant amount of rework (WASTE). What Poka-Yoka applications could be put in place to insure all six holes are drilled and rework is eliminated?

Situation 3
Nine times in the last year a truck has become wedged beneath a bridge that has an 11 foot clearance. The bridge is a set of railroad tracks and the underpass was created to allow traffic to pass without being stopped for trains. There is a traffic sign 100 feet before the underpass warning of the 11 foot clearance and the bridge has its clearance painted on the side. What would you do to stop the trucks from hitting this bridge?