Faurecia Excellence System

Group Quality Department

Quality System Efficiency

The 6 Quality Basics

-> Poka Yoke
Purpose: Poka Yoke methodology

Scope: all production sites

Check that this is the latest version of this document.

FAU-S-PS-0650 / EN issue 01
 1 – Definition

A poka-yoke is a simple and reliable device that physically prevents:

9 either the error leading to the defect
9 or the transmission of the defect to the next workstation

Of course, not producing the defect in the first place is always preferable to detecting the
defect afterwards. (An once of prevention is worth a pound of cure, as they say.)

There are two types of poka -yoke:

9 Product: based on inherent product characteristics such as shape or symmetry
9 Process: based on certain product characteristics in order to avoid errors in the
manufacturing process.

The poka-yoke must be permanent .

The poka-yoke must be “foolproof” (i.e. it must be impossible to bypass).

Only an authorized person (e.g. Gap Leader, Supervisor) may intervene.

Situations to avoid: - reset button
- master key
- simple disconnection (e.g.from electrical outlet)

The poka-yoke must be foreseen upstream, right from the product/process design phase.

Examples of poka-yokes in everyday life:

3.5” diskettes can not be inserted upside down because one corner is cut. If the cut corner
is on the wrong side, it hits something and the diskette will not go all the way in.
In an ATM (cash dispenser), you have to remove your credit card before you can get your
money. This prevents you from forgetting your card in the machine.

FAU-S-PS-0650 / EN issue 01 - 2/ 8
 2 - Examples

PRODUCT poka-yoke:

Example: guide pins of different shapes and/or sizes

Without poka-yokes: defect possible With poka-yokes: defect

(reversed assembly) cannot be created

PROCESS poka-yoke :

Example: poka-yokes are built into the process to check that an operation has been
properly performed:

Screw-counter. If a screw is
missing or there is insufficient
torque, the part is prevented
from moving on to the next
workstation.

The conveyer stops

automatically if the seat is in the
wrong position for delivery
(headrest too high).

FAU-S-PS-0650 / EN issue 01 - 3/ 8
 3 – Identification of Process Poka-Yoke

To improve identification and tracking of process poka-yokes, each one is given a

reference number and represented on the plant layout diagram as shown:

PKY
001

PKY
002
PKY ___

FINAL
INSPECTION

FAU-S-PS-0650 / EN issue 01 - 4/ 8
 4- Visual Management

This red symbol is PERMANENTLY fixed

to the machine

Red means the poka-yoke is out of order.

The label shows the poka-yoke number

and the parameter that must be inspected
100%.
PKY002
OUT OF ORDER The system must be repaired within 8
100 % INSPECTION REQUIRED hours of the breakdown. If necessary, a
PARAMETER:
spare parts stock is created.

Green means the poka-yoke works

properly.

Validation must take place before applying

this symbol.

The label shows the poka-yoke number

and the parameter that is under control.
PKY002
WORKING
PARAMETER:

This symbol must be visible and accessible to the operator, who is responsible for visual
management

The poka-yoke
100 % Inspection
= PKY002
OUT OF ORDER
100 % INSPECTION REQUIRED
ON PARAMETER :

doesn’t work

The poka-yoke
= PKY002

IN ORDER
ON PARAMETER :

works
No inspection of this
characteristic

FAU-S-PS-0650 / EN issue 01 - 5/ 8
 5- Validation and capitalisation

Validation:

Each poka-yoke has a dedicated validation sheet :(FAU-F-PS-0222) specifying:

9 parameter or critical characteristic
9 validation method: master part (correctly identified), description of incorrect operation

It is the operator who validates poka-yokes:

9 at each start-up: start of shift or after breakdown (see guide “OK 1st part")
9 using validation sheet FAU-F-PS-0222

As soon as the operator sees a poka-yoke malfunction, s/he must immediately notify the
Supervisor. The operator logs the time of the malfunction in order to organize an inspection
of all the parts produced up to this point.

The operator must be trained to conduct 100% inspection of the parameter when the poka
yoke fails.

Capitalisation:

Each poka-yoke has a definition sheet (FAU-F-PS-0221). This document is managed and
updated by the UAP Quality correspondent and contains the following information:
9 Detection method
9 Location
9 Explanation of improvements
9 Effects and costs

FAU-S-PS-0650 / EN issue 01 - 6/ 8
 Appendix: suggestions for designing Poka-Yokes

Identify objects by characteristics such as:

9 weight
9 dimensions
9 shape

To detect operator deviation or errors, use devices:

9 with physical contact (e.g. contactor, lever)
9 without physical contact: photo-electric cells (transmission, reflection)

To detect deviation from set values, use measurement systems:

9 pressure,
9 temperature
9 electricity (voltage,amperage)
9 vibration
9 rpm
9 data transmission

FAU-S-PS-0650 / EN issue 01 - 7/ 8
 General Information

Author :
Group QSE
Date :
12 January 2004

Aim of the modification:

Complete revision of the previous version

Cancels and replaces:

• FAU S PS 0220

Associated documents:
• FAU S PS 0610
• FAU S PS 0620
• FAU S PS 0630
• FAU S PS 0640
• FAU S PS 0660
• FAU F PS 0221
• FAU F PS 0222

FAU-S-PS-0650 / EN issue 01 - 8/ 8