Poka Yoke, developed by Shigeo Shingo in the 1960s, is a crucial concept in Lean

Manufacturing and Six Sigma methodologies. The term Poka Yoke translates to Mistake
Proofing or Error Proofing in Japanese. Shingo introduced the idea to differentiate between
human mistakes and defects in manufacturing. He emphasized that defects occur only when
human errors are allowed to proceed unchecked to the customer.

The core principle of Poka Yoke is to design processes in a way that either eliminates the
possibility of errors at the source or ensures that errors are easily detected and corrected
before they can cause defects. By preventing mistakes from becoming defects, Poka Yoke
enhances quality and reduces waste, making it an integral part of Lean and Six Sigma's drive for
continuous improvement and operational efficiency.

This concept has since been widely adopted in various industries to enhance quality control and
minimize waste.

Types of Poka Yoke

1. Error Prevention (Prevent Mistakes at Source)

Poka Yoke devices are designed to make errors impossible in the first place. This approach
involves modifying the process so that it physically prevents the error from occurring. The key
is to build fail-safes into the system that ensure the operator cannot proceed incorrectly.

Examples:

 Guiding Pins: Inserting parts into assembly lines in a way that only allows correct
positioning (e.g., USB drives that fit only one way).
 Color-Coding: Using color codes to match parts to their correct locations, preventing
incorrect assembly.

2. Error Detection (Catch Mistakes Before They Become Defects)

In situations where prevention isn't possible, Poka Yoke systems are designed to detect mistakes
as soon as they happen. This allows for immediate correction before defects occur. These
mechanisms often alert operators or halt the process automatically.

Examples:

 Sensors and Alarms: Using sensors that detect missing components or misalignments
and stop the process when errors are identified.
 Weight Sensors: For assembly processes, weight sensors can ensure the correct number
of components have been added before the product moves forward.
3. Immediate Feedback

Poka Yoke systems often provide immediate feedback when an error is detected, enabling
operators to address the problem instantly. This reduces rework and prevents defective products
from advancing to the next stage of production.
 Poka Yoke System: Methods and Devices
There are three key methods used in Poka Yoke systems for error prevention and detection, and
they can be applied to both the control and warning approaches:

1. Contact Method

 Description: Involves testing for specific product parameters, such as size, shape, or
color, to identify any errors.
 Control Approach Example: The machine stops if a part is not aligned correctly.
 Warning Approach Example: A sensor triggers a light or sound when the wrong-sized
part is detected.
 Devices Used: Limit switches, toggle switches, and physical contact sensors.

2. Fixed-Value Method

 Description: This method tracks the number of items or steps in a process and ensures
all necessary actions are completed.
 Control Approach Example: A machine stops if fewer than the required number of
screws is detected in an assembly.
 Warning Approach Example: A counter signals a warning if a step is skipped but
doesn’t stop the machine.
 Devices Used: Counters, digital sensors, and trackers.

3. Motion-Step Method

 Description: This method checks if the sequence of operations is followed correctly.

 Control Approach Example: The machine halts if an operator skips a required step in
the process.
 Warning Approach Example: A signal alerts the operator if the process is out of order,
but the process continues.
 Devices Used: Sensors that detect movement or order of operations.

Sources of Errors in Manufacturing

Errors in manufacturing can be classified into six categories, commonly referred to as the 6Ms:

1. Man (Human Error): Mistakes made by operators, often due to fatigue, lack of training,
or inattention.
2. Machine: Equipment malfunctions or failures that contribute to defects.
3. Method: Errors due to poor procedures, incorrect sequences, or outdated processes.
4. Material: Faulty, insufficient, or wrong materials used in production.
5. Measurement: Inaccurate measurements leading to defects or failures in quality control.
6. Mother Nature (Environment): External factors like humidity, temperature, or dust
affecting the process.
Poka Yoke Examples in Manufacturing

 Machine safety interlocks: Machines that will not start until safety doors are fully
closed.
 Fixture design: Only allows parts to be held in the correct orientation.
 Tolerance testing fixtures: Stops operation if part dimensions fall out of tolerance.
 Safety and power guards: Prevent accidents on machines with moving parts.
 Sensor-based part detection: Missed drilling or missing parts are detected at the next
station.
 Press machines with two-hand operation: Forces operators to keep a safe distance from
the machine.

Additional examples include:

 Buzzers/alarms: Signal issues without stopping the process.

 Guide pins/locator pins: Ensure proper part placement.
 Counting devices: Ensure the correct number of items is processed.
 Limit switches: Prevent further operations if an error is detected.
 Area sensors: Detect the presence or absence of objects.
 Presence checks: Ensure all necessary components are in place.
 Two-hand operations: Require both hands to be used to start machines, ensuring
operator safety.
 Color codes: Guide correct placement and assembly of parts.

Benefits of Poka Yoke Implementation

 Elimination of Mistakes: Prevents errors and defects before they occur.

 Early Detection and Correction: Identifies defects as soon as they occur, ensuring
prompt corrective action.
 Improved Product Quality: Reduces defects and enhances the quality of products.
 Cost Reduction: Reduces costs related to poor quality, rework, and waste.
 Fewer Customer Complaints: Ensures that defective products don’t reach customers,
improving satisfaction.
 Process Improvement: Eliminates unnecessary steps and ensures better quality control.
 Higher Productivity: Streamlined processes result in faster production with fewer
errors.
 Less Operator Burden: Reduces the need for constant vigilance and makes jobs easier.
 Enhanced Customer Satisfaction: A direct result of improved product quality and
reliability.

Poka Yoke, by eliminating or catching errors early, significantly improves operational efficiency,
product quality, and customer satisfaction across industries

Control devices in Poka Yoke systems are mechanisms that detect an error and automatically
stop or shut down a machine or process to prevent defects from occurring. These devices
ensure that the process cannot continue until the error is corrected, ensuring high-quality output
and preventing defective products from advancing in production.

Here are some common examples of control devices:

1. Limit Switches

 How It Works: A limit switch detects the position or movement of an object. If a part is
misaligned or missing, the limit switch triggers and stops the machine.
 Example: In a conveyor belt system, if a product is not properly positioned at a certain
station, the limit switch detects the misplacement and halts the operation until the product
is corrected.

2. Safety Interlock Switches

 How It Works: Safety interlock switches prevent a machine from operating unless
certain conditions are met, such as a door being closed.
 Example: A machine won’t start unless its safety guard is closed, preventing accidents or
unsafe operations.

3. Proximity Sensors

 How It Works: Proximity sensors detect the presence or absence of an object within a
specific range. If the sensor doesn’t detect the object, the machine stops.
 Example: If a component is not in place for assembly, the sensor detects this absence and
halts the operation until the component is positioned correctly.

4. Pressure Sensors

 How It Works: These sensors detect whether the correct amount of pressure is being
applied in a process.
 Example: A packaging machine that applies too much or too little pressure to seal a
package will stop to prevent defective packaging.

5. Machine Guards with Interlock Systems

 How It Works: Machine guards are equipped with sensors that detect if the guard is
opened or tampered with. If the guard is not securely closed, the machine will stop or
refuse to operate.
 Example: A press machine with a guard that must be fully closed before the machine can
start pressing, ensuring operator safety.

6. Positioning Jigs and Fixtures

  How It Works: These are mechanical devices that ensure parts are positioned correctly
before any operation can begin. If the part is not in the correct position, the machine
cannot proceed.
 Example: A jig used in drilling operations ensures that the workpiece is in the correct
position, preventing the machine from starting if the part is misaligned.

7. Automatic Shutoff Valves

 How It Works: These valves automatically stop the flow of liquids or gases if pressure,
temperature, or another factor is outside the safe range.
 Example: In chemical processing, if the pressure in a tank exceeds safe limits, the valve
will close to stop the process and prevent damage or accidents.

8. Photoelectric Sensors

 How It Works: These sensors use light beams to detect the presence or absence of
objects. If the sensor detects an issue, it stops the machine.
 Example: In a bottling line, if a bottle is missing or misplaced, the sensor detects it and
halts the line until the problem is fixed.

9. Two-Hand Control Devices

 How It Works: Machines that require the operator to use both hands to activate the
machine, ensuring that hands are clear of moving parts.
 Example: Press machines require the operator to press two buttons simultaneously, one
with each hand, to prevent accidents.

10. Counter Systems

 How It Works: Counters track the number of operations (e.g., number of screws
fastened) and stop the machine if the required number is not met.
 Example: An assembly station that requires six screws to be inserted will stop if fewer
screws are used, preventing incomplete assemblies.

11. Barcode Scanners

 How It Works: Barcode scanners ensure that the correct parts or materials are being
used in a process. If the wrong item is detected, the process is stopped.
 Example: In a warehouse, if a worker scans the wrong part for shipping, the system will
not proceed until the correct part is scanned.

12. Weight Sensors

 How It Works: These sensors measure the weight of items or components to ensure the
correct amount is being used.
  Example: In a packaging line, if the weight of a product does not match the expected
value, the system stops to prevent underfilled or overfilled products.

13. Error Detection Cameras (Vision Systems)

 How It Works: Cameras equipped with error detection software analyze products for
visual defects or inconsistencies. If a defect is found, the system halts.
 Example: A camera that checks for correct labeling or alignment of products on a
production line, stopping the line if an issue is detected.

Examples
Poka Yoke, or mistake-proofing, is not just limited to manufacturing; it is widely used in daily
life to prevent errors and make tasks easier and more foolproof. Here are some common
examples of Poka Yoke in daily life:

1. USB Plug Design

 How It Works: USB connectors are designed in such a way that they can only be
inserted in the correct orientation.
 Error Prevention: This prevents users from inserting the plug the wrong way, avoiding
damage to the port or device.

2. Microwave Oven Door

 How It Works: Microwave ovens won’t operate unless the door is properly closed.
 Error Prevention: The door mechanism prevents the microwave from running when
open, ensuring safety by avoiding exposure to harmful radiation.

3. ATM Card Slot

 How It Works: ATM machines require the card to be inserted in a specific orientation
(chip first, face up) to process the transaction.
 Error Detection: If the card is inserted incorrectly, the machine won’t process it and will
alert the user, preventing misuse or damage.

4. Childproof Medicine Caps

 How It Works: Many medicine bottles have childproof caps that require a specific
action (like pressing down and twisting) to open.
 Error Prevention: This prevents children from accidentally opening the bottle and
ingesting harmful medication.
5. Car Gear Shift Lock

 How It Works: Automatic cars often have a shift lock that prevents you from shifting
out of "Park" unless you press the brake pedal.
 Error Prevention: This ensures the car cannot accidentally roll away or cause an
accident by shifting into drive or reverse without the brake being applied.

6. Laptop Power Cable with Magnetic Connector

 How It Works: Some laptops use a magnetic power connector that easily disconnects if
pulled.
 Error Prevention: This prevents the laptop from being pulled off a table or damaged if
someone trips over the cable.

7. Elevator Door Sensors

 How It Works: Elevators have sensors that detect obstacles (like a person or object) and
prevent the doors from closing.
 Error Detection: If someone or something blocks the door, the elevator will
automatically stop closing to avoid injury.

8. Washing Machine Door Lock

 How It Works: Modern washing machines often have locks that prevent the door from
opening during the wash cycle.
 Error Prevention: This prevents water from leaking out and stops anyone from opening
the door while the machine is operating.

9. Gasoline Nozzle Shape

 How It Works: The nozzles for different fuel types at gas stations are designed
differently to prevent users from filling a car with the wrong type of fuel (e.g., diesel
nozzles are wider and won’t fit into regular gasoline cars).
 Error Prevention: This avoids potential engine damage from using the wrong type of
fuel.

10. Toaster Eject Mechanism

 How It Works: Toasters automatically eject the bread once it's toasted to a certain level.
 Error Prevention: This prevents the bread from burning if you forget to take it out.

11. Hotel Keycard Power Switch

 How It Works: Many hotel rooms require you to insert your keycard into a slot to turn
on the power.
  Error Prevention: This ensures you can’t leave the lights or air conditioning running
when you’re not in the room, conserving energy.

12. Three-Prong Electrical Plugs

 How It Works: Electrical plugs with three prongs ensure that appliances are grounded,
and the plug can only be inserted in one orientation.
 Error Prevention: This reduces the risk of electrical shocks or damage by ensuring
proper grounding.

13. Automated Bill Payment Reminders

 How It Works: Many banking apps and services send reminders before bill due dates.
 Error Detection: These reminders help prevent missed payments, avoiding late fees or
service interruptions.

14. Smoke Detectors with Low-Battery Beeps

 How It Works: Smoke detectors emit periodic beeps when their battery is low.
 Error Detection: This alerts homeowners to replace the battery before the detector stops
functioning, ensuring it works during emergencies.

15. Seatbelt Warning Light/Chime

 How It Works: Cars often have sensors that detect when the driver or passengers haven’t
fastened their seatbelts, triggering a light or chime.
 Error Detection: This encourages everyone to buckle up for safety, preventing the car
from being driven without seatbelts fastened.

16. Car Fuel Cap Warning Light

 How It Works: Some cars have a dashboard warning light or alarm that goes off if the
fuel cap isn’t tightened properly after refueling.
 Error Detection: This prevents fuel vapor from escaping and ensures the car’s fuel
system remains sealed and efficient.