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Poka Yoke Definition
- Techniques that help operators avoid mistakes in their work caused by choosing the wrong part, leaving out a part, installing a part backwards, etc.
- It involves the implementation of fail-safe ways methods that detect or prevent human and machine error at or near the source
- It provides instant feedback and prevention of quality problems
Definition of a Defect
- The result of any deviations from product specifications that lead to customer dissatisfaction
Definition of an Error
- Any deviation from a specified manufacturing process
- The result of an error is shown in a defect.
Prevention Device
- Is a device or process that prevents errors from occurring or prevents these errors from creating defects
- Examples: part locators, part present sensors
Detection Device
- Is a device that will detect a defect or concern and initiate a corrective action
- Examples: vision system, limit sensors

Causes of Errors
- Processing omissions
- Processing errors
- Error in setting up the work piece
- Missing parts
- Improper item
- Processing wrong work piece
- Operations errors
- Adjustment, measurement, dimension errors
- Errors in equipment maintenance/repair
- Errors in preparation of tools/jigs
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Areas with high error potential Adjustments
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Areas with high error potential Tooling and tooling changes
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Areas with high error potential Dimensions/specifications
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Areas with high error potential Many mixed parts
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Areas with high error potential Multiple steps
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Areas with high error potential Infrequent production
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Areas with high error potential Lack of an effective standard
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Areas with high error potential Symmetry
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Areas with high error potential Asymmetry
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Areas with high error potential Rapid repetition
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Areas with high error potential High volume
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Areas with high error potential Environmental conditions
Implementation
- Develop team
- Create Error Proofing Implementation Sheet
- Identify and describe defect
- Determine location the defect was found & made
- Identify root cause
- Current process and deviations from standards
- Propose and implement improved process
- Measure
- Standardize
Guidelines for error proof devices
- Low cost, easy to implement
- Prevent the ability to make a defect / prevent the defect from being passed on
- Provide immediate feedback
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