Poka-Yoke

Shingo advocates the concept of zero quality control by arguing that inspection processes or the use of statistical control should be completely eliminated. He believes that quality should be controlled at the source of the problem and not after the problem has manifested itself. He recommends that inspection should be incorporated within the process and at the point where the problem has been identified and from where it should be eliminated.

Poka-Yoke

He considers that statistical quality control tends to focus on the effect (subsequent errors related to operators), rather than the cause which is due to process imperfections and abnormalities. He is the developer of a concept called Poka-Yoke which means foolproofing. A Poka-Yoke device or system is one that prevents incorrect parts from being made or assembled or easily identifies any flaw or error.

Poka-Yoke - Principles

Control upstream, close to the source of problem by for example incorporating monitoring devices to warn on defects in materials or abnormalities within the process. Establish control mechanisms to deal with different problems to enable operators to know which problem to cure and how to cure it with minimal disruption to the operating system.

Poka-Yoke - Principles

Take a step-by-step approach by taking small strides, simplifying control systems and having economic viability in mind. Efficiency, technological sophistication, available skills, work methods have all got to be carefully studied for effective use of Poka-Yoke.

Poka-Yoke - Principles

Do not delay improvement by overanalyzing. Although many manufacturers main objective is to achieve closeness between design manufacturability, many Poka-Yoke ideas can be implemented as soon as the problems have been identified with no cost at all to the companies concerned. Poka-Yoke encourages inter-departmental co-operation and is main vehicle for continuous improvement because it encourages continuous problem-solving activity.