Poka Yoke: Mistake and Error Proofing in Japan

Topics: Shigeo Shingo, Poka-yoke, Error Pages: 3 (635 words) Published: May 31, 2011
Lean 101

|PokaYoke | |(Error-proofing/Fool-proofing) |

| | |POKAYOKE: Japanese for 'mistake-proofing'. Mistake-proofing and fool-proofing devices made by designing items, processes, or procedures so | |that mistakes physically or procedurally cannot happen. PokaYoke workers are not blamed for the errors, but instead find ways to keep errors | |from becoming defects. A service request-taking example is a screening for request input developed from traditional request patterns that | |question requests falling outside the pattern. The “outlying” requests are then examined, often leading to the discovery of inputting errors | |or action based on misinformation. A poka-yoke is sometimes called a baka-yoke. [Also called Fool-Proofing, Error-Proofing, | |Mistake-Proofing, or Zero Quality Control (ZQC)]. |

Lean 101 - PokaYoke (Error-proofing)

|Lean = Doing it right the first time |

PokaYoke (pronounce the ending e, poka-yoki), or mistake- or fool-proofing, is a Japanese word for an extremely simple concept that, using common sense, has been applied forever. It’s the use of simple mechanisms to prevent mistakes from being made by workers, without requiring special effort on their part.

Pokayokes or fail-safe devices are generally very simple and often inexpensive visual prompts that prevent errors in the work being done. Either the worker is alerted that a...
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