Poka Yoke

Poka-yokes fall into one of three categories: contact methods, fixed-value methods, and
motion-step methods

Contact methods are based on some type of sensing device which detects abnormalities in the
product's shape or dimension and responds accordingly.

Fixed-value methods are used in processes where the same activity is repeated several times,
such as tightening of bolts. This method frequently involves very simple techniques, such as
methods that allow operators to easily track how often this activity has been performed.

Motion-step method is useful for processes requiring several different activities performed in
sequence by a single operator. This is similar to the fixed-value situation in that the operator is
responsible for multiple activities but instead of performing the same activity multiple times the
operator performs different activities.

Contact Type Warning Type

A steel pin on a fixture keeps
incorrectly placed parts from
Contact Method fitting properly.
A device on a drill counts the
number of holes drilled in a
work piece; a buzzer sounds
if the work piece is removed
before the correct number of
holes have been drilled.

Light sensors determine if each Bolts are tightened with a

crayon is present in each box; if wrench dipped in paint. Bolts
Fixed-value Method a crayon is missing, the with no paint on them are still
machines will stop automatically untightened.

A device detects when each

A simple proximity switch opens
after all components are loaded
Motion-Step Method
in the proper order
component is removed from
a dispenser; if a component
is not removed, the device
alerts the assembler before
he can move on to another
unit.
Activity

The screw slips very often when the worker try to tighten it. Can you fool proof it
so that the worker is able to place the flat head screwdriver onto your redesign
screw.

Slip