Poka-Yoke

POKA-YOKE

MEANS

ZERO DEFECTS

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 Poka Yoke

Japanese technique for mistake-proofing

Poka - inadvertent (unintentional) mistake
Yoke prevent

Developed in the 1960s

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The cause of defects lie in worker errors, and
defects are a result of neglecting those errors
mistakes will not turn into defects if worker
errors are discovered and eliminated
beforehand - Shingo

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 Poka-Yoke Device Categories

Prevention Device - Make errors impossible

DetectionDevice - Make errors visible to

the operator

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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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 Basic Function of Poka-Yoke

Three basic poka-yoke functions to use against

defects:
1. shut down a machine or operation
2. control a process or operation
3. warn that a defect has occurred

Recognizing that a defect is about to occur is called

PREDICTION.
Recognizing that a defect has happened is called
DETECTION.
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 Top 10 Errors that Cause Defects

1. Processing omissions (a step was forgotten)

2. Processing errors (something was done incorrectly)
3. Error in setting up the work piece
4. Assembly omissions (a part was forgotten)
5. A wrong part / item was included
6. Wrong work piece
7. Operations errors (incomplete information, procedures not
followed)
8. Adjustment, measurement, dimensional errors
9. Equipment maintenance errors
10. Errors in preparation of tools, fixtures, blades, etc

Error: When any condition necessary for successful

processing is wrong or absent.

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Other Defect Causes

Misunderstanding instruction or procedure.

Errors in identification (e.g.: part and/or placement
recognition).
Errors made through lack of experience
Pace (too fast or too slow).
Lack of standards, expectations, procedure, or
instructions.
Incomplete information adjustment or placement
errors.

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 What Does Poka-Yoke Do?
Eliminates the cause of an error at the source;

Detects an error as it is being made;

Detectsan error soon after it has been made

but before it reaches the next operation.

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Two Strategies for Zero Defects

1. DONT MAKE IT!

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 1. Dont Make It!

Dont make product you dont need.

Themore you make, the greater the

opportunity for defects.

Follow just-in-time principles by only making

what is needed, when it is needed in the
amount needed.
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Two Strategies for Zero Defects

2. Build Safeguards

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2. Build Safeguards

The user is an expert in finding defects.

Therefore build safeguards into the production

process.

Quality
can be built into products by
implementation of Poka-Yoke.

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Poka-yoke systems consist of three primary methods:

1. Contact
2. Counting
3. Motion-Sequence

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Physical Contact Devices

Limit Switches Toggle Switches

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Contact Device

An example of a
contact device using a
limit switch. In this
case the switch makes
contact with a metal
device sensing its
present. If no contact
is made the process
will shut down.

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Counting Method

Another approach is to count the number of parts or components required

to complete an operation in advance. If operators finds parts leftover
using this method, they will know that something has been omitted from
the process.

I have an extra
part. I must have
omitted a step!

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Motion-Sequence Method

The third poka-yoke method uses sensors to determine if a motion or a step

in a process has occurred. If the step has not occurred or has occurred out
of sequence, then the sensor signals a timer or other device to stop the
machine and signal the operator.

This method uses sensors and photo-

electric devices connected to a timer.
If movement does not occur when
required, the switch signals to stop
the process or warn the operator.

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 Motion-Sequence Method

In this example, each step of the machine cycle is wired to an indicator board
and a timer. If each cycle of the machine is not performed within the required
time and sequence, the indicator light for that step will be turned on and
the machine will stop.

Machine Indicator Board

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Types of Sensing Devices
1. Physical contact devices
2. Energy sensing devices
3. Warning Sensors

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 Physical Contact Sensors
These devices work by
physically touching
something. This can be a
machine part or an actual
piece being manufactured.

In most cases these

devices send an
electronic signal when
they are touched.
Depending on the process,
this signal can shut down
the operation or give an
operator a warning signal.
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Touch Switch
Used to physically detect the presence or
absence of an object or item-prevents missing
parts.

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 Energy Sensors
These devices work
by using energy to
detect whether or
not an defect has
occurred.

Fiber optic

Vibration
Photoelectric
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 Warning Sensors
Color Code
Warning sensors
signal the operator
that there is a
problem. These
sensors use colors,
alarms, lights to get
the workers
attention !

Lights connected
to Micro switches
& timers
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