Poka Yoke

Poka Yoke (ポカヨケ) is a Japanese term, which is translated as “fail-safing” or “mistake-proofing”, and it isn’t usually translated. Poka-yoke is a mechanism or device (manufacturing plant) in the production process (often in the lean manufacturing process), which helps the worker to avoid (yokeru) mistakes (poka). Its purpose is to eliminate defective products using prevention, correction and warnings on the human mistakes that cause these defects. The whole concept was formalized and introduces as a term by Mr. Shigeo Shingo as part of the TPS (Toyota Production System). It was originally named as baka-yoke , which meant “fool-proofing”, but the name was changed to more tolerant Poka-Yoke.

Use of the Poka Yoke in practice: Poka Yoke principle helps to prevent unnecessary errors. Poka Yoke can be mechanical or electrical manufacturing plant, mechanism or device through which you cannot make a bad product. The device prevents confusion of parts, confusion of the sequence of assembly operations in the production process, such as incorrect installation of any element either mechanically or electronically. The device therefore prevents the mechanic to contine installing the product on, as long as something is missing or it is not properly fitted.