Poka Yoke

Use Realistic Tolerancing and Poka-yoke for Process Control

Many organizations attempt to improve their processes. The first instinct for many new quality personnel is to attempt 100 percent inspection. A more experienced approach to quality control is to control your inputs to eliminate defects. Consider the following scenario for an organization that had a limited capital budget but needed to ensure its product…


How to Poka-yoke CAD Drawings

The following question has been posed on many Internet discussion forums: Has anyone poka-yoked a computer-aided design (CAD) system? The goal of poka-yoke, or mistake-proofing, is to design a process or mechanism that prevents an error from occurring. In the world of machine and industrial design, CAD systems are one of the best forms of…


Work Instructions for Mistake Proofing

1. Use cross-functional teams (CFT) approach to mistake proofing. 2. Selection of process for mistake proofing. During the third phase of advanced product quality planning (APQP), the CFT shall identify the processes, where, due to avoidable human errors, the rating of “occurrence” and/or “detection” have increased thereby increasing the risk priority number (RPN) for the process. Poka-yoke techniques…


How Mistake Proof Are Your Processes?

It was a Japanese manufacturing engineer named Shigeo Shingo who developed the concept that revolutionized the quality profession in Japan. Originally called “fool proofing” and later changed to “mistake proofing” and “fail safing” so employees weren’t offended, poka yoke (pronounced “poh-kah yoh-kay”) translates into English as to avoid (yokeru) inadvertent errors (poka). The result is…