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Poka-Yoke Technique -Brief Summary

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 Poka-Yoke Technique – Brief Summary
Stefanos Varntanian and Diana Pancera
1. Introduction

The world today is highly competitive and there is an expectation from any organisation or
company to deliver reliable products that are characterized by their high quality and zero
defects at an acceptable for the customer price. Different mechanisms and tools have been
developed to achieve manufacturing excellence and best possible operational performance,
such as Six Sigma, JIDCO, JIT, Poka-Yoke etc. This report will be focusing on the Poka-Yoke
method as a valuable strategy in improving the quality of an operations process. [1]

2. History

Poka-Yoke is a concept that originated in the 1960s in Japan by Shigeo Shingo, who was
working at Toyota as an industrial engineer. The original terminology Baka-Yoke, meaning
‘fool-proofing’, was deemed too disrespectful and dishonourable and was altered eventually
to Poka-Yoke, which translates to ‘mistake-proofing’. The basic idea behind the phrasing, was
that it is not sufficient and acceptable by any means the manufacturing of a product with even
the smallest traces of defect or nonconformity. Poka-yoke is utilized as a prevention
mechanism which has the focal point of identification and elimination of anything that might
cause a degree of variance in the manufacturing process, as this could potentially lead to
defects. The cost-effective solutions provided by Poka-yoke are directed at the source of the
defects and are not only easy to comprehend but also quite simple to implement. In turn, this
leads the quality management system (QMS) of any company to attain higher levels of
performance. Therefore, Poka-yoke is considered to be a good method and integral factor for
the continuous improvement strategy in many top Japanese as well as international
companies. [1, 2]

3. Definition

A systematic literature review of the Poka-yoke method revealed that over 50 diverse
definitions exist, as the majority of researchers approached the theoretical aspect of Poka-
yoke from different angles and had a slight contrasting understanding of its general
applications. There is no official acceptable uniform definition of Poka-yoke, which makes
studying or comparing results from articles rather complicated. A list of some of the
definitions used for Poka-yoke is provided in Table 1. [3]

Tab. 1: Various interpretations of Poka-yoke. [3]

Author Definition
Hinckley and Barkan [4] Poka-yoke utilizes devices in order to
prevent errors during the manufacturing
process that could lead to defective
products. It then shuts down the process
and after identifying the root cause of the
problem, eliminates it.
 Robinson [5] Poka-yoke is a simple mechanism that
applies a warning or control device, which
enables the detection, prevention and
correction of defects at their source, so that
clients get the highest quality product
possible.
Stewart and Melnyk [6] Poka-yoke is an approach focusing on
quality improvement, a systemic technique
or a simple unique device that impedes a
defect from reappearing after it was
eliminated. If operators adhere to the
correct steps and proper procedures, then
the outcome will be a defect free product.
Pakdil et al. [7] Poka-yoke is a straightforward and cost-
effective device operated during the
manufacturing process with the aim to
prevent defective products.
Vidor and Saurin [8] Poka-yoke can be described as a device or
even a system that is able to detect as well
as prevent nonconformities and
abnormalities that negatively impact the
quality of a product.

4. Functions of Poka-yoke

Advanced manufacturing technologies can only lead to minimization of potential errors,

because human mistakes are still common in the production environment and potentially
have a positive impact on the cost expenses. The implementation of Poka-yoke in completely
eliminating any kind of mistakes is still not very widespread and a lot of managers are not
even familiar with this term. [3]

Poka-yoke can either detect defection after it has taken place or predict an error that is about
to transpire. This rather innovative technique commences with the examination of possible
problems, followed by identification of any parts in regard to dimension, shape, size and
weight and ends with the analysis of potential deviation from the nominal processes.
According to the functionality of the procedure occurring, there are three various types of
Poka-yoke: [1]

- Shutdown Poka-yoke
A shutdown occurs after the Poka-yoke device reviews several critical parameters and
determines that the process that materializes is proceeding to leave the tolerance zone. This
is a hint that a product with certain defects is being manufactured or has already been
produced. This type of Poke-yoke works as a prevention mechanism and guarantees that
there is no chance of a defective product at the production line. [2]
 - Control Poka-yoke
The Poka-yoke device as control method can be described as regulatory in working and is
integrated with the process equipment. This makes it impossible to manufacture a product
with nonconformity characteristics, as it will simply not progress to the next stage of the
production line. This type of Poke-yoke also provides assurances that any product will be
without any types of defects. [2]

- Warning Poka-yoke
This Poka-yoke technique is alerting an operator at the production sector through buzzer
sounds or lamp flashes that there is a defect in the manufacturing procedure. This requires
urgent interference from a worker and a correction of the process that is causing the errors,
so that the next products in line will appear defect free. This method does not provide
certainty that the products will be of the highest quality due to the reliance on the human
factor. If the warning from the Poke-yoke device is ignored or not noticed on time, then it is
the irresponsible conduct of the operator liable for the mistakes that occur in the production
line. [2]

Out of the three types of Poka-yoke mentioned above, the control one is the best and most
effective device in terms of the corrective approach towards a defect as it leads to an
immediate shutdown of the production line until all errors are eliminated. Three different
types of control Poka-yoke exist: [9]

- Contact method
The Poka-yoke device is able to identify specific abnormal characteristics regarding the shape
or dimension of a product. [9]

- Fixed-value method
This technique is used when there is a constant repeat of the same activity, giving operators
an opportunity to determine the performance of this activity and it ascertains that a certain
number of movements is generated. [9]

- Motion-step method
This method is utilized when various activities are taking place in sequence and it regulates
that the fixed motions of the production process are followed properly. [9]

5. Types of Poka-yoke devices

Errors during the operation process, as can be seen in Figure 1, can occur at any given time
point. The process starts with activity 1 and ends with the finished product at operation m.
During this procedure, each activity is potentially susceptible to product failure or causing
defects to the finalized product. The first error can happen at point A1, which is the beginning
of operation and additional mistakes could appear anywhere between the activities A1 and
An. There is a possibility of errors developing at the point areas A, B and C or even during
product handling within different work operations. It is also poignant to note that each
operational step must be carried out in accordance with the formalized design solution. [3]
Fig. 1: Simplified work process containing various operations that need to be realized in order
to deliver the finished product. [3]

Different types of Poka-yoke devices can prevent errors from transpiring at various stages of
the operations process and deliver products without any kind of defect and of high quality.
There are six particular devices that need to be mentioned: [3]

I. Passive device
The Passive device Poka-Yoke (PPY) utilizes visual effects such as light and sounds that act as
a warning about high probability of an error during the operation procedure. It does not
prevent mistakes from occurring, but simply indicates which operational stages are
dysfunctional and should be bypassed. [3]

II. Active preventive

The Active Preventive Poka-Yoke (APPY) addresses the issue of errors prevention, by being
active from the start of the operation process until the end, when a defect free product is
materialized. [3]

III. Active, for detection

The Active Detection Poka-Yoke (ADPY) is an electro-mechanical device that aims to identify
abnormalities on products and requires corrective adjustments for those that do not abide
by high quality standards. This of course impairs the operations process and is reflected in
requiring more materials, additional time and labor. [3]

IV. Hybrid active, preventive

The Hybrid Active Preventive Poka-Yoke (HAPPY) is a combination of I and II and can be
considered the best and optimal variation of the Poka-yoke system regarding investigating
errors. The cost of implementing this rather complicated device is higher in comparison to
the above-mentioned devices but is complemented by successfully preventing defects and
improving worker efficiency with the help of audio-visual signals. [3]

V. Hybrid active, detection

The Hybrid Active Detection Poka-Yoke (HADPY) is a combination of I and III and is regarded
as a desirable device for the operation procedure. It merges audio-visual signals with an active
preventive mechanical mechanism that leads to better efficiency in all stages of the work
process and guarantees zero errors. The training of operators on this device is simple and
does not require high expenses. [3]
 6. Methodology of Poka-yoke

The theoretical analysis of the Poka-yoke method can be summarized in six steps: [1]

I. Identification of the problem

All the complaints from clients internally and externally are compiled and classified in terms
of the number of complaints filed, the quantity of the defects, defects in materials and any
other data associated with mistakes during production. These results will be key in the
development and eventually implementation of a Poka-yoke method for the specific problem
a company is facing. [1]

II. Observation at workstation

A detailed analytical study will be completed on-site and the reasons for causing the problem
in the manufacturing process will be investigated with the aid of a fishbone diagram. The
causes could be related to the machine, the production method, employees or even the
material used. This will provide a better understanding of the defects, variations from the
normal procedure and any possible imperfections. [1]

III. Brainstorming for idea

The third stage of the methodology includes a brainstorming session, where all employees
provide a solution to the current problem being studied based on their unique skillset and
creativity. [1]

IV. Select best idea

The best idea is chosen from the brainstorming discussion depending on certain criteria’s such
as associated cost, implementation time of the solution, number of required changes in the
system, complexity etc. [1]

V. Implementation plan
A plan is development concerning implementing and installing the selected solution. This step
also encompasses the necessary material requirements as well as the processing of the
material and the manufacturing procedure. [1]

VI. Monitoring and sign off

The final phase incorporates the inspection of products from any defects and the
performance of the specific Poka-yoke system is under review. [1]

7. Conclusion

The purpose of implementing Poka-yoke is to minimize or at best eliminate human errors

during the manufacturing procedure, so that a defect product of low quality does not reach
customers hands. The main idea behind this system is to be able to prevent any causes that
might lead to mistakes in the operation process by constant monitoring all production stages.
This requires synergy with workers, that can apply corrective measures when Poka-yoke
identifies the possibility of defects. [10]
 8. References

[1] R. Kumar et al, Poka-Yoke technique, methodology & design, Indian Journal of Engineering,
Vol. 13, Issue 33, 2016.
[2]. S. Anderson, “Poka-Yoke: Mistake-Proofing as a Preventive Action”, The Informed
Outlook Reprint, Vol. 7, No. 3, 2002.
[3] M. Lazarevic et al, A systematic literature review of Poka-yoke and novel approach to
theoretical aspects, Journal of Mechanical Engineering, 2019.
[4] Hinckley et al., Selecting the best defect reduction methodology, Quality and Reliability
Engineering International, Vol. 12, No. 6, p. 411–420, 1996.
[5] Robinson H., Using Poka-Yoke techniques for early defect detection, In Sixth International
Conference on Software Testing Analysis and Review (STAR 1997), p. 1-12, 1997.
[6] Stewart D. et al, Effective process improvement developing poka-yoke processes,
Production and Inventory Management Journal, Vol. 41, No. 4, p. 48–55, 2000.
[7] Pakdil F. et al, A systematic approach to reduce human and system-related errors causing
customer dissatisfaction in a production environment, Total Quality Management & Business
Excellence, Vol. 20, No. 1, p. 129–137, 2009.
[8] Vidor G. et al, Concepts and features about poka-yoke systems: a literature review.
Revista Produção Online, Vol. 11, No. 2, p. 344–368, 2011.
[9] S. Shigeo et al, A study of the Toyota production system from an industrial engineering
viewpoint, Productivity Press. 1989.
[10] M. Dudek-Burlikowska et al, The Poka-yoke method as an improving quality tool of
operations in the process, Vol. 36, Issue 1, 2009.

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