Poka Yoke is a technique used in making the integrity of a process more robust and is often described as error proofing. Implemented correctly, and comprehensively, Poka Yoke literally means that the process in question is incapable of generating a defect.
The process is simple and is often used in conjunction with Team-Based, Problem Solving as part of a permanent corrective action.
Poka Yoke means Zero Defects
In today’s business environment customers expect and demand Zero Defects! Most quality-focused individuals will recognise that 100% inspection does not generate 100% OK parts. Even 200% inspection (doing the job twice) still only secures around 80% OK production. Therefore it is imperative that the process is designed in such a way that it is only possible to make OK parts.
The fundamental objective of Poka Yoke is to shift the emphasis from post-production inspection to detecting the actual error or root cause that can lead to the defect being produced. After identification of the root cause, a countermeasure is developed that will prevent the recurrence of that particular failure mode. This countermeasure will be in the form of a physical change to the process; such that no matter what takes place the specific failure will be prevented from reoccurring.
By continually applying Poka Yoke to the process the entire operation will eventually be incapable of generating any failure. In some complex operations there may be many instances of Poka Yoke such that the overall integrity of the process is secured.
The Lean Group has extensive experience in helping Teams design and implement Poka Yoke solutions in the development of robust processes. Our approach to Poka Yoke is based upon what is practical, what works in the real world - and what doesn't.
Participants will develop a complete understanding of Poka Yoke in a safe environment before applying their knowledge to real issues in the work place and under the support and guidance of The Lean Group. This approach can significantly reduce the impact of quality concerns on any business.
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