Poka-Yoke Case Study

1. INTRODUCTION:
Managers throughout the ages worried and are still worrying about nature of errors that perhaps generate in any day organizational work routine. It could be in Product manufacturing, Manufacturing process or even in Services Offerings. The factual reason for this is that any workplace mistake can create loss of money and goodwill for the business and through management action leading to loss of job for the staff involved in the said known or unknown lapse. In today's critical scenario where Health, Social Responsibilities of Corporations, Safety and Environment matters are at the highest degree for a thriving business, any bacterial amount of error could be fatal for its existence in the Market.Therefore this research is aimed
The man behind our inspiration to research extensively in this topic was Mr.Shigeo Shingo from Japan. Mr.Shingo was a Japanese Industrial Engineer considered to be world's leading expert in manufacturing practices who formulated Poka-Yoke meaning 'mistake-proofing'. A poka-yoke is a mechanism in a lean manufacturing process that helps an equipment operator avoid (yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur. The concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota
Standard Operating Procedures (SOP) should also be compulsorily developed to document error detection, reduction, eliminations and prevention techniques. Automation is also a great way to eliminate human intervention in business process and manufacturing assembly lines. Lean Six Sigma would also be a methodology that relies on a collaborative team effort to improve performance by systematically removing waste, error causing elements and thereby combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste: Time, Inventory, Motion, Waiting, Over production, Over processing, Defects, and