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Faurecia Excellence System

Group Quality Department

Quality System Efficiency

The 6 Quality Basics -> Poka Yoke

Purpose: Poka Yoke methodology

Scope: all production sites

Check that this is the latest version of this document.

FAU-S-PS-0650 / EN issue 01

1 Definition
A poka-yoke is a simple and reliable device that physically prevents: either the error leading to the defect or the transmission of the defect to the next workstation Of course, not producing the defect in the first place is always preferable to detecting the defect afterwards. (An once of prevention is worth a pound of cure, as they say.) There are two types of poka -yoke: Product: based on inherent product characteristics such as shape or symmetry Process: based on certain product characteristics in order to avoid errors in the manufacturing process. The poka-yoke must be permanent . The poka-yoke must be foolproof (i.e. it must be impossible to bypass). Only an authorized person (e.g. Gap Leader, Supervisor) may intervene. Situations to avoid: - reset button - master key - simple disconnection (e.g.from electrical outlet) The poka-yoke must be foreseen upstream, right from the product/process design phase.

Examples of poka-yokes in everyday life: 3.5 diskettes can not be inserted upside down because one corner is cut. If the cut corner is on the wrong side, it hits something and the diskette will not go all the way in. In an ATM (cash dispenser), you have to remove your credit card before you can get your money. This prevents you from forgetting your card in the machine.

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2 - Examples

PRODUCT poka-yoke: Example: guide pins of different shapes and/or sizes

Without poka-yokes: defect possible (reversed assembly) With poka-yokes: defect cannot be created

PROCESS poka-yoke : Example: poka-yokes are built into the process to check that an operation has been properly performed:

Screw-counter. If a screw is missing or there is insufficient torque, the part is prevented from moving on to the next workstation.

The conveyer stops automatically if the seat is in the wrong position for delivery (headrest too high).

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3 Identification of Process Poka-Yoke

To improve identification and tracking of process poka-yokes, each one is given a reference number and represented on the plant layout diagram as shown:

PKY 001

PKY 002

PKY ___


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4- Visual Management
This red symbol is PERMANENTLY fixed to the machine Red means the poka-yoke is out of order. The label shows the poka-yoke number and the parameter that must be inspected 100%. The system must be repaired within 8 hours of the breakdown. If necessary, a spare parts stock is created.



Green means properly.




Validation must take place before applying this symbol. The label shows the poka-yoke number and the parameter that is under control.

This symbol must be visible and accessible to the operator, who is responsible for visual management

The poka-yoke doesnt work

100 % Inspection



The poka-yoke works No inspection of this characteristic
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5- Validation and capitalisation

Validation: Each poka-yoke has a dedicated validation sheet :(FAU-F-PS-0222) specifying: parameter or critical characteristic validation method: master part (correctly identified), description of incorrect operation It is the operator who validates poka-yokes: at each start-up: start of shift or after breakdown (see guide OK 1st part") using validation sheet FAU-F-PS-0222

As soon as the operator sees a poka-yoke malfunction, s/he must immediately notify the Supervisor. The operator logs the time of the malfunction in order to organize an inspection of all the parts produced up to this point. The operator must be trained to conduct 100% inspection of the parameter when the poka yoke fails. Capitalisation: Each poka-yoke has a definition sheet (FAU-F-PS-0221). This document is managed and updated by the UAP Quality correspondent and contains the following information: Detection method Location Explanation of improvements Effects and costs

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Appendix: suggestions for designing Poka-Yokes

Identify objects by characteristics such as: weight dimensions shape To detect operator deviation or errors, use devices: with physical contact (e.g. contactor, lever) without physical contact: photo-electric cells (transmission, reflection) To detect deviation from set values, use measurement systems: pressure, temperature electricity (voltage,amperage) vibration rpm data transmission

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General Information

Author : Group QSE Date : 12 January 2004 Aim of the modification: Complete revision of the previous version Cancels and replaces: FAU S PS 0220 Associated documents: FAU S PS 0610 FAU S PS 0620 FAU S PS 0630 FAU S PS 0640 FAU S PS 0660 FAU F PS 0221 FAU F PS 0222

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