Poka Yoke: 4 Steps of How to Set up Mistake Proofing 【Toyota Production System】

Poka Yoke: 4 Steps of How to Set up Mistake Proofing  【Toyota Production System】


Here is the story of “Poka Yoke” that
is said to aim at zero defects. [Intro Video] Hi, this is Mike Negami, Lean Sigma Black Belt. The Poka Yoke is very famous in the manufacturing
industry. Pretty much everyone knows the word in the
industry. “Poka” means a “Mistake” and “Yoke”
means “To Avoid” in Japanese. Therefore, Poka Yoke means “Mistake Proofing”. Since we are all humans, everyone makes mistakes. However, mistakes in business could lead to
major losses or safety issues. Ideas and techniques that ensure mistakes
never happen are Poka Yoke. The most familiar example is a USB cable. This cable, you’re not physically able to
plug it in upside down. Another example is, one of my house’s under
sinks looks like this underneath. If by any chance you dropped something important
in it, you can still get it out of the pipe. This is also Poka Yoke. In the manufacturing industry, there are two
types of Poka Yoke: Control Poka Yoke and Warning Poka Yoke. Control Poka Yoke is more ideal. By changing process steps or tweaking your
tools, Control Poka Yoke is to make it mechanically impossible for a mistake to happen in your
process. If you can’t achieve Control Poka Yoke,
you should consider Warning Poka Yoke. This Poka Yoke alerts operators by color or
sound when they are about to make a mistake, so they can prevent it. A car’s headlights are a good example. When you leave your headlights on and stop
the engine, the previous generation of cars alerted us by sound. This is the Warning Poka Yoke. But recent cars turn the lights off by themselves. Cars have evolved and now do the Control Poka
Yoke. So how can we utilize Poka Yoke in our work
or company? I’ll introduce the four steps to carry out
a Poka Yoke. Step 1 is to keep firmly in mind: “Everyone
makes mistakes, but I’m responsible for those mistakes as a manager.” You may think that that is just a mental theory,
but as long as you blame others or your workers, you cannot think of any Poka Yoke ideas. It’s more important than you think to change
your mindset to “I’ll make a Poka Yoke process. In order to do that, what should I do?” In service operations, since we didn’t have
this concept before, and we have few examples, this mindset is particularly important. We can go to the next step after achieving
this. Step 2 is “Find the most mistake-ridden
work or process.” In Lean Sigma, we always deal with Vital Few,
a few very important factors. The impact after solving the vital few mistakes
is more significant than solving the others. Step 3 is “Find the root cause of the vital
few mistakes and design Control Poka Yoke or Warning Poka Yoke.” For that, you should conduct the 5 Why Analysis
and make an Ishikawa Diagram, then you can find their root causes. Step 4 is “Make an SOP (Standard Operating
Procedure) and Checklist, then train operators according to it.” For operations using Excel or PDF, you may
be able to practice actual Poka Yoke, for example, by using the data validation function
or Macros. But, frankly speaking, you may have rare chance
to be able to set up Poka Yoke for service operations. In that case, you should design a standard
operation that produces less mistakes and document the standard operation as an SOP. You should also make a Checklist that lists
the important steps of the new process. Have the operators check this Checklist during
their operations. Also, the new method must be user-friendly
for the operators, otherwise, they would stop using it and return to their old method. Please aim for zero mistakes with this Poka
Yoke concept. Thank you very much for viewing. Please click the ‘Subscribe’ button. Also click and watch my other related videos. Thanks.

About the Author: Michael Flood

22 Comments

  1. English isn't the best, but very clear points and a very helpful video, thanks Econoshift you're the best xox

  2. ほんとうに 私のために やくにたつです、ありがとうございます。It is really helpful for me sir, thank you so much

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