Poka Yoke - a Japanese Word Explanation

Introduction

Poka Yoke is a Japanese word which can be broken down into “poka” which means “inattention” and yoke which stands for “avoid”. In a whole it means avoiding mistakes. It is a cheap and simple technique which detects, signals and eliminates the chances of errors. There are two approaches used in implementing Poka Yoke technique:

(1) Control: which is to take an action to prevent a defect and

(2) Warning: which is to give signal when an error has occurred

Example of Poka- Yoke implementation in manufacturing industry -

1) Redesigning of a small switch assembly process by Shigeo Shingo

In a switch assembly factory, workers would often forget to insert spring under the switches. Shigeo Shingo introduced two steps, first prepare two required springs and place them in a placeholder. This way the worker won’t forget to place the spring.

2) Use of magnets in Grain packaging plant

In a grain packaging plant it is often found that small metal pieces fall of with the grains and decrease the overall quality. It is imperative to remove these metal pieces and hence manufacturers use a magnet to detect and remove them before they are forwarded for packaging.

3) Use of Light curtains from dangerous machines

Light curtains are optic-electronic devices that can be used to safeguard manufacturing personals from dangerous machineries such as presses and winders. It also removes traditional machine guarding.

4) Detecting blue color personal equipment in food industry

Blue colored food articles are rarely found in food industry and hence the personal equipment like gloves of workers are kept in blue color for easy detection.

Example of Poka- Yoke implementation in services industry-

1) Use