Define it:
Poka-Yoke (ポカヨケ, PO-kah yo-KAY) is a Japanese term meaning “avoid mistakes”. It originates from manufacturing guru, Shigeo Shingo and the Toyota Production System in the 1960’s. It’s a lean manufacturing tool that is used not only to reduce mistakes but also to streamline processes, reduce waste, improve efficiency, and create better products.
Examples:
Manufacturing: Interlock switches which can turn off a machine when a safety guard is lifted, Magnets to capture metal objects in food manufacturing, Containers which are standardized to fit only a specific amount of product.
Product Design: Sauce bottle with opening at the bottom, Auto shut off on appliance doors when opened, Overflow outlets in sinks
Customer Service: Queue management systems, A bell on a door to alert staff on a new customer, Requiring ID info to be entered before completing a transaction
Everyday Life: Automatic breaking systems in your car, Spell check, Lawn mowers with a bar that must be held to operate the blade,
How to Poka-Yoke:
- Identify where an error is occurring.
- Determine the source of an error. Why is it occurring?
- Determine how you eliminate the error. Can you change the step in the process? Can you make the correct process easier than the error?
- If you can’t eliminate the error, can you detect it? How could you minimize errors?
- Choose the best method for each error, test the methods, implement and analyze the results over time.
Something to Consider:
When thinking of Poka-Yokes, keep in mind that the best solutions will be:
- Simple
- Low Complexity
- Low Cost
- Automatic
- Located at the problem site
- Improves Quality, Service, Safety, or Efficiency
The Biz Cache 
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