Poka-Yoke

• What
• Why
• When
• How
• Where

What is Poka-Yoke

Poka-Yoke (Error Proofing) is the principle of incorporating error detection and prevention into the design of production processes.

Why Poka-Yoke

General advantages

• Making it impossible to make mistakes (or at least makes them easy to notice)
• It simplifies training

Reduces waste types

• ☐ Conveyance
• ☐ Inventory
• ☐ Motion
• ☐ Waiting
• ☐ Overproduction
• ☐ Overprocessing
• ☑ Correction

When to use Poka-Yoke

Essential conditions

Non-essential conditions

How to implement and use Poka-Yoke

Implementation

Levels of Poka-Yoke (Error Proofing) designs:

1. Good = Defects are detected before continuing to the next process
2. Better = Defects are detected when an error is made
3. Best = It is impossible for errors to occur

Good designs:

• Are automatic
• Are simple
• Are inexpensive
• Give prompt feedback
• Give prompt action(prevention)

E.g. a power plug that fits only one way.

Use

• The operator uses it by default because it is incorporated into the design.

Where to find it

IASSC Body of Knowledge:

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About the Author

Floris Lap is an IASSC-certified Lean Six Sigma Black Belt and founder of Procestimal. He empowers organizations to maximize value and reduce waste through practical Lean Six Sigma solutions—contributing to a more sustainable world where businesses thrive with minimal resources. Contact us

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