Poka Yoke

Error Proofing
g
Poka-Yoke = Error Proofing

DEFINITION
A device which prevents a process from
• making an error or Î prediction
• passing a defect to user Î detection

When a defect is predicted or

an error detected:
• the process is shut down or
• a control prevents going ahead or
• a warning
i i sentt
is
Error Proofing 2
Errors are the root causes –
Defects are symptoms

input output
ERROR DEFECT

CAUSE EFFECT
Broken
machine Non-conforming part

IIncorrectt transport
t t Damaged
equipment part

Reject Broken tool

Poor raw material
3

Error Proofing 3
Two types of Poka‐Yoke
o types o o a o e

WARNING Indicates an error situation

requiring intervention
CONTROL
Stops production
Prevents mistakes

Bip! Bip
Line 12 is
stopped!!!
Visual aids
12

120 V
1.5 A

Error Proofing 4
Drill Poka Yoke
Buzzer or light

Limit
switches

No Poka Yoke Stop Poka Yoke Warning Poka Yoke

Screw Poka Yoke

Screwdriver can slip Screwdriver can’t slip

and
d scratch
t h surface
f and
d scratch
t h surface
f
Go-Nogo Poka Yoke

φ 3.0
+0
0.00
00
Before After
f 3 0 - 0.05 φ 3.1 - 0.05
+0
0.50
50

φ 3.0 - 0.05
+ 0.00

φ 3.0 - 0.05
+ 0.00
φ 2.9 - 0.05
+ 0.50

Make both sides the same so it

can’t be assembled incorrectlyy

φ 2.8 - 0.05
+ 0.00
Poke-Yoke

Correct Incorrect

POKA YOKE

Correct insertion Prevents wrong

side insertion

Error Proofing 8
Drill Guide

Error Proofing 9
Dowel Pin Checks

Error Proofing 10
Diet or regular
g cola?

TRANSPARENT COVER

REGULAR

DIET COCA
ORANGE COLA SPRITE
ROOT BEER DIET SPRITE

DIET
STAMPED
COVER

ROOT BEER

Error Proofing 11
Position detector

F il
Fragile

Keep in
upright
position

Error Proofing 12
Street Grate
Street Grate

The cover can fall

in the sewer (when
moved)

The cover cannot fall in

the sewer. But it can be
dangerous
g for cyclists.
y

This cover
is error proof

Error Proofing 13
Document Poke-Yoke

Ten operations are covered by

a group of instruction charts
St 1:
Step 1 processing
i iinner di
diam. Poka Yoke:
Bound the instruction
38
charts so the operator can
see only the operation
Step 2: processing outer diam. being performed
40
0

Step 1: processing inner diam.

38
Operator accidentally uses
the dimensions for Step 2
while
hil performing
f i StStep 1

Error Proofing 14
Poke-Yoke

Typist Stand
The activity symbol is used when an object is
created, changed or added to. This includes the
giving or receiving of information as well as planning
or calculating.

The transportation symbol is used when something

i moved
is d ffrom one area tto another.
th ThThe movementt
of paper
of paper within
within a
a workstation
workstation is
is not
not considered
considered
Transportation.

The activity symbol is used when an object is

created, changed or added to. This includes the
giving or receiving of information as well as planning
or calculating.

The transportation symbol is used when something

is moved from one area to another. The movement
of paper within a workstation is not considered
Transportation.

The activity symbol is used when an object is

created, changed or added to. This includes the
giving or receiving of information as well as planning
or calculating
calculating.

The transportation symbol is used when something

is moved from one area to another. The movement
of paper within a workstation is not considered
Transportation.

Error Proofing 15
Quality
y Files Present and Ordered

Error Proofing 16
Others
• Opening more than one filing cabinet drawer
• I
Inserting
ti a CD/DVD th the wrong way up
• Putting diesel pump nozzle in an unleaded petrol tank
• Over tightening a cap with a ratchet system on it
• Loosing a tool that is attached by a chain to its point of
use
Poka-Yoke = Error Proofing

DEFINITION
A device which prevents a process from
• making an error or Î prediction
• passing a defect to user Î detection

When a defect is predicted or

an error detected:
• the process is shut down or
• a control prevents going ahead or
• a warning
i i sentt
is
Error Proofing 18