Share

Poka Yoke: What it is and examples [Complete Guide].




The Poka Yoke system, created by Shigeo Shingo,
seeks to avoid errors in production processes. It is based on designing
processes and products that minimize mistakes, and its main objective
is to improve quality and efficiency.



In this article we will see what Poka Yoke is, its objectives and
advantages, as well as its different types and applications.



What is the Poka Yoke system?



The term Poka Yoke is a quality concept and technique developed in Toyota’s production system, within the framework of the Toyota Production System
(TPS), which is an efficient and waste-free manufacturing methodology.
It comes from Japanese and is commonly translated as “error-proof” or
“fail-safe”.



The Poka Yoke system was developed in the 1960s by engineer Shigeo Shingo, precisely with the aim of avoiding errors in production processes. Shingo was a pioneer in the implementation of continuous improvement techniques to effectively identify and correct defects.



Objective



The main objective of the Poka Yoke system is to eliminate
opportunities for errors in production and logistics processes. It seeks
to guarantee the quality of the final product and reduce the costs
associated with errors, thus improving the operational efficiency of
manufacturing companies.



The Poka Yoke system facilitates continuous improvement
through its ability to prevent errors and ensure process reliability.
By proactively identifying and correcting defects, companies can move
toward operational excellence and total quality in their operations.



Advantages of the Poka Yoke system



The main advantages of the Poka Yoke system are closely linked to the
fact that it does not require drastic changes in the processes:



  • It allows improvements to be implemented without significantly altering the structure of existing processes.
  • It facilitates the gradual adoption of corrective measures without interrupting production.
  • Minimizes risks associated with abrupt changes in procedures.
  • It is especially attractive for companies with limited resources for extensive modifications.
  • Offers effective solutions without the need for significant investments in infrastructure.
  • Adapts to different scales of production, from small companies to large corporations.


Types of Poka-Yoke



There are several types of Poka-Yoke, each designed to address
different types of errors or specific process situations. The most
common types of Poka-Yoke are:



  • Contact Poka-Yoke: This type of Poka-Yoke involves
    the use of physical devices or sensors to prevent errors by detecting
    incorrect contact or the absence of a component. For example, a device
    that prevents a machine from operating unless all components are
    correctly assembled.
  • Sequence Poka-Yoke: Focuses on ensuring that
    process steps are followed in the correct sequence. It may involve the
    use of visual cues or physical restraints that prevent a step from being
    omitted or performed out of order.
  • Position or Location Poka-Yoke: This approach is
    used to ensure that components or products are in the correct position
    during the manufacturing process. Devices such as guides or visual
    markers can help maintain proper alignment.
  • Quantity Poka-Yoke: Focuses on avoiding errors
    related to the quantity of items needed in a process. They can include
    counters, presence sensors or visual alerts that indicate when the
    quantity is not adequate.
  • Poka-Yoke of operation sequences: Prevents errors
    by ensuring that operations are performed in the correct sequence. It
    can include devices that only allow certain operations after completing
    others, thus ensuring proper workflow.
  • Information Poka-Yoke: Focuses on avoiding errors
    caused by lack of information or misunderstandings. They may include
    clear instructions, labels, or visual cues that guide operators on how
    to perform a task correctly.
  • Time Poka-Yoke: Seeks to avoid time-related errors,
    such as inadequate duration of an operation. They may include timers,
    alarms, or time constraints to ensure that actions are performed at the
    correct intervals.


How to implement the Poka Yoke system?



1. Identification of sources of defects



  • Analyze existing processes in detail to identify possible sources of errors.
  • Consult employees involved in those processes to obtain valuable information.
  • Use tools such as flowcharts and root cause analysis to identify root causes of defects.


2. Prioritization and choice of method



  • Once the sources of defects have been identified, it is essential to prioritize them according to their impact on quality.
  • Select the most appropriate method to address each source of error,
    considering the feasibility and effectiveness of the proposed solutions.
  • Establish a clear action plan and define responsibilities for implementing the necessary corrections.


3. Measuring effectiveness through checklists



  • Develop detailed checklists to evaluate the effectiveness of implemented measures.
  • Establish key performance indicators to measure defect reduction and process quality improvement.
  • Conduct periodic follow-ups to verify compliance with new practices and adjust as necessary.


Poka Yoke System Applications



Some of the most frequent applications where this Poka Yoke system can be used are:



  • Complicated processes with multiple steps
  • Activities that require high precision
  • Error-prone or unpredictable industries
  • Presence of external factors that can influence the final result


These situations can occur frequently in the automotive manufacturing industry, where the Poka Yoke system is applied to assembly lines to ensure that parts are correctly positioned, or in the manufacture of electronic products, such as cell phones or computers, to ensure accuracy in the assembly of components. It is also very useful in the pharmaceutical industry, to prevent errors in drug packaging and labeling, and in healthcare, to prevent errors in drug administration or surgical procedures.



In short, the Poka-Yoke system is like having a “mistake-proof
friend” on the production line. It prevents misunderstandings, keeps
things in order and ensures that everything flows smoothly. Whether in
complicated processes, in activities requiring extreme precision, or in
sectors prone to slippage, Poka-Yoke helps us avoid errors and improve
efficiency.



Recent post

APPIA GROUP leads the logistics transformation with advanced solutions. In an increasingly competitive business environment, Logistics 4.0 is revolutionizing the supply chain. One of the fundamental pillars of this transformation is warehouse automation robots a trend that not only optimizes logistics processes, but

APPIA GROUP drives the growth of ARIES LOGISTIC by connecting it with high value customers.
By
Marina Medina

Related post

Today, it is essential to meet fast delivery times and to be able to respond quickly to our customers’ demands. In this respect, well-planned procurement allows us to forecast delivery times with precision. But what exactly does it consist of? Procurement is a

On many occasions we have talked about the importance of implementing a warehouse management software (WMS) to automate processes within the warehouse, so that we can mitigate day-to-day incidents caused by human error. However, it is crucial to remember that a warehouse does

Online shoppers are very frustrated when, after an often lengthy search, they find the ideal product, only to discover that it is not available due to lack of stock. For the customer it can be a big disappointment, but for an e-commerce company