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POKA YOKE

mWhat is Poka - Yoke ?

Poka - Yoke means


 Mistake Proofing or
 Fool Proofing or
 Fail safing
POKA YOKE

áheory behind Poka - Yoke

mPrompt feed
m100 % Inspection back and action
by detection as soon as
devices defects occur

100 % inspection by the devices is superior to Statistically based


sampling inspections for reducing defects
POKA YOKE

Poka - Yoke devices eliminate defects


without SQC
BUá
Poka - Yoke method is difficult where
physical detection is technically or
economically not feasible
POKA YOKE

Where Poka - Incorporate Poka -


Yoke is technically Yoke functions
or economically into Successive
not feasible in self check systems
- check system..
POKA YOKE

Source Inspection with Poka - Yoke method


Operator error is a ï  of defects which is
a 
áo eliminate defects we need to pursuit
causes of defects than treating results
MEANS
Errors must be identified and eliminated
beforehand
POKA YOKE

Conventional method
CAUSE RESULá
Operator Neglected Defect
Error Error appears

Source inspection with Poka - yoke method


CAUSE RESULá
Operator Error Feedback Zero
Error discovery and action defects

Keep errors from turning into defects


POKA YOKE

SOURCE INSPECáION POKA - YOKE SYSáEM

Cause
Error 100 %
Inspection
Check
and
Feedback 0 Prompt
feedback
Action and
action
Benefits of POKA - YOKE

Poka - Yoke builds quality into processes


Poka - Yoke helps to avoid defects even when
inadvertent errors are made
Poka - Yoke eliminates defects without SQC
(Statistical Quality Control) and hence
eliminates QC inspection
Poka - Yoke free Operators by taking out tasks
which require vigilance and memory
áypes of POKA - YOKE

 Poka - Yokes devices are of 3 types

áype I - Eliminates error


áype II - Prevents error
áype III - Indicates error
áypes of POKA - YOKE

áype I - Will not allow any abnormality to occur


áype II - When abnormality occurs, either it
stops or shuts down the process or
makes the assembly difficult
áype III - When abnormality occurs, it calls for
attention of Operator through alarm.
Alarm could be audio or visual signals
MOSá COMMON HUMAN ERRORS

Errors due to forgetfulness


Errors due to Misunderstanding
Errors due to slowness
Errors due to lack of standards
Errors in identification
Willful errors
Errors made by amateurs
Unintentional errors
Surprise errors
POKA YOKE APPLICAáIONS

Processing omissions
Processing errors
Missing parts
Adjustment errors
Improper, damaged , poorly designed JIG
Wrong parts
Set up errors
Missing operations