Poka-Yoke

CH-8

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Outline
 History
 What is Poka-Yoke?
 Characteristics
 Types of Poka Yokes
 Industrial Applications
 Inspection Techniques
 Cost of quality
 Everyday Examples

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History

 Poka-yoke (pronounced "POH-kah

YOH-kay") was invented by Shigeo
Shingo in the 1960s.

 The term "poka-yoke" comes from

the Japanese words "poka"
(inadvertent mistake) and "yoke"
(prevent).

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What is Poka-Yoke?
 A poka-yoke device is any
mechanism that either prevents a
mistake from being made or makes
the mistake obvious at a glance.
 As Shingo writes, "The causes of
defects lie in worker errors, and
defects are the results of neglecting
those errors. It follows that
mistakes will not turn into defects if
worker errors are discovered and
eliminated beforehand„ [Shingo
1986, p.50].
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Characteristics

 they are simple and cheap.

 they are part of the process.

 they are placed close to where the

mistakes occur.

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 Types of Poka Yokes

 prevention.
 engineers the process so that it is
impossible to make a mistake.
 remove the need of correction.

 detection.
 signals the user when a mistake has
been made.
 they do not enforce the correction.

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Industrial Applications

 Yamada Electric

 General Motors

 Software Quality

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Inspection Techniques

 judgment inspection.
 sorting the defects out
 informative inspection.
 Successive checks
 Self-checks
 source inspection.
 before the fact

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 Cost Of Quality
 Cost of achieving
good quality
Prevention
Appraisal

 Cost of poor
quality
Internal failure
costs
External failure
costs

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 Everyday Examples

3.5 inch diskettes cannot be inserted unless diskette

is oriented correctly. This is as far as a disk can be
inserted upside-down. The beveled corner of the
diskette along with the fact that the diskette is not
square, prohibit incorrect orientation.

Fueling area of car has three error-proofing devices:

1. insert keeps leaded-fuel nozzle from being inserted
2. tether does not allow loss of gas cap
3. gas cap has ratchet to signal proper tightness and
prevent overtightening.
New lawn mowers are required to have a
safety bar on the handle that must be pulled
back in order to start the engine. If you let go
of the safety bar, the mower blade stops in 3
seconds or less.
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