Poka Yoke

Definition

Japanese term which means «mistake-proofing system » (literal translation is “avoiding” –yokeru- “inadvertent errors” -poka-). It’s a human-mistakes risk limitation method. Poka Yoke can be a process as well as a physical tool.

Poka Yoke’s objective is to achieve the «Zero default». Its systematic application even leads to the «Zero control ».

Poka Yoke will help to manufacture straight away flawless products, generating fewer to be retouched products therefore stock’s reduction. Poka Yoke is thus an actor of the Supply Chain performance for its inclination to reduce stocks

Example

• In a Warehouse, a colored label sticked on pakcagings to indicate visually the customer, product’s type… is a Poka Yoke allowing the forklift driver to avoid addressing errors.

• «Pick to light»: on an assembly line, above the racks of parts appear green lights = the part is to be taken. Above the racks of other parts, red lights appear = the part is not to be taken.

• Poka Yoke through the product’s design. The shape of a product can act as Poka Yoke. (Example plug)