Mistake Proofing

Mistake Proofing is best defined as:

– Using wisdom, ingenuity or serendipity to create devices
allowing a 100% defect free step 100% of the time.

Poka-Yoke is the Japanese term for mistake proofing or to avoid

“yokeuro” inadvertent errors “poka”.

See if you can find

the Poka-Yokes!

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 Traditional Quality vs. Mistake Proofing

Traditional Inspection
Result
Sort
Worker or Do Not Do Defective At Other
Machine Error Anything Step

Discover Take Action/ No Next

Error Feedback Defect Step

Source Inspection
“KEEP ERRORS FROM
TURNING INTO DEFECTS”

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 Styles of Mistake Proofing

Two states of a defect are addressed with Mistake Proofing.

ERROR ABOUT TO OCCUR ERROR HAS OCCURRED

DEFECT ABOUT TO OCCUR DEFECT HAS OCCURRED

(Prediction) (Detection)

WARNING SIGNAL WARNING SIGNAL

CONTROL / FEEDBACK CONTROL / FEEDBACK

SHUTDOWN SHUTDOWN
(Stop Operation) (Stop Operation)

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 Mistake Proofing Devices Design

Hints to help design a Mistake Proofing device:

– Simple
– Inexpensive
– Give prompt feedback
– Give prompt action (prevention)
– Focused application
– Have the correct people’s input

BEST ...makes it impossible for errors to occur

BETTER …allows for detection while error is being made
GOOD ...detects defect before it continues to the next operation

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 Types of Mistake Proof Devices

Contact Method
– Physical or energy contact
with product
1 Guide Pins of
Different Sizes

• Limit switches
• Photo-electric beams
Fixed Value Method 2 Error Detection
and Alarms
– Number of parts to be
attached/assembled etc.
are constant
– Number of steps done
3 Limit Switches
in operation
• Limit switches
Motion-step Method 4 Counters

– Checks for correct sequencing

– Checks for correct timing
• Photo-electric switches 5 Checklists
and timers

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Everyday examples of mistake-proofing:
• Home
– Automated shutoffs on electric coffee
pots
– Ground fault circuit breakers for
bathroom in or outside electric circuits
– Pilotless gas ranges and hot water
heaters
– Child proof caps on medications
– Butane lighters with safety button
• Computers
– Mouse insertion
– USB cable connection
– Battery insertion
– Power save feature
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Mistake Proofing Examples
• Automobile
– Seat belts
– Air bags
– Car engine warning lights
• Office
– Spell check in word processing software
– Questioning “Do you want to delete”
after depressing the “Delete” button
on your computer
• Factory
– Dual palm buttons and other guards on
machinery
• Retail
– Tamper proof packaging
– Bar code price recognition
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 Advantages of Mistake Proofing as a Control Method

Mistake Proofing advantages include:

– Only simple training programs are required
– Inspection operations are eliminated and the process is simplified
– Relieves operators from repetitive tasks of typical visual inspection
– Promotes creativity and value adding activities
– Results in defect free work
– Requires immediate action when problems arise
– Provides 100% inspection internal to the operation

The best resource for pictorial examples of Mistake Proofing is:

Poka-Yoke: Improving Product Quality by Preventing Defects.

Overview by Hiroyuki Hirano. Productivity Press, 1988.)

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 Defect Prevention Culture and Good Control Plans

Involve everyone in Defect Prevention:

– Establish Process Capability through SPC
– Establish and adhere to standard procedures
– Make daily improvements
– Invent Mistake Proofing devices

Make immediate feedback and action part of culture

Do not just stop at one Mistake Proofing device per product

Defect Prevention is needed for all potential defects

Defect Prevention implemented MUST be

documented in your living FMEA for the
process/product

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