What is a Poka-Yoke process?
“Poka-Yoke”, which means “error prevention” in Japanese, is the process that is used to prevent and solve defaults during the production, which reduces the need of quality inspections aftewards.
The process can be applied in any situation in which error prevention is important in any industry. Some errors that are often reduced or erased from operations can be:
- Missing parts;
How is a Poka-Yoke process implemented?
One of the major differentiator factor in Poka-yoke is that is makes the distinction between defects and mistakes. distinguishes between defects and mistakes. Where, a defect is an error that is repeated and that may arrive to the customer, a mistake is a ponctual error. Therefore, the process aims to reduce potential mistakes along the assembly, in order to reduce defects.
The process aims to avoid errors by engaging in preventive measures. It includes the following steps:
Build a multifuncitonal team
Select the process
Map the process
Identify eventual risks (ways and reasons) that may appear
Find the source
Choose the best fitted method
Implement and validate
After the process is concluded, it is important to keep a continuous improvement mindset, in order to ensure that processes are frequently optimized and that results are achieved in the best way possible.