POKAYOKE Poka-yoke was invented by shigeo shingo in the 1960’s. the term poka-yoke comes from the japenese words “poka” (inadvertent mistake) and “yoke” (prevent) the essential idea of poka yoke is to design your process so that mistakes are impossible or atleast easily detected and corrected. It is a simple principle that can lead to massive savings. In the production processes workers commit inadvertent errors. Shigeo shingo developed ‘mistake proofing’ and source inspection system that, employees can identify and absolutely eliminate product and process errors.
Characteristics of good pokayoke decices: * They are simple and cheap. If they are too complicated or expensive, their use will not be cost effective. * They are part of the process, implementing what shingo calls “100%” inspection. * They are placed close to where the mistakes occur ,providing quick feedback to the workers so that the mistakes can be corrected 8 principles of improvements by pokayoke * Build quality in processes * All inadvertent errors and defects can be eliminated * Stop doing wrong and start doin right * Don’t think of excuses. Think about how to do right 60% chance of success is good enough. Implement idea now. * Mistakes and defects can be reduced to zero when everyone works together to eliminate. * Ten heads are better than one. * Seek out true cause 5Ws ond one H. THREE LEVELS OF POKAYOKE The three levels at which your company can effect pokayoke * Eliminating spills, leaks, and accidental losses at the source. * Detecting unintended loss that is in the process of occurring, but before it becomes a problem. * Detecting loss after it has occurred, but bfore the contingency indicator is triggered. APPLICATION OF POKAYOKE Manual operations where worker vigilance is needed. * Where mispositioning or misalignment can occur. * Where adjustment is required. * Where teams need common-sense tools and not another BMP to remember. * Where statistical process control is difficult to apply or where it has been ineffective. * Where attributes, not measurements, are important. * Where training costs and employee turnover are high. * Where mixed model production occurs. * Where external failure costs dramatically exceed internal failure costs. “YOU DO THE POKAYOKE AND YOU TURN YOUR COMPANY AROUND THAT’S WHAT ITS ALL ABOUT”