POKA-YOKE

INTRODUCTION
Pronounced as POH-kah YOY-Kay
Poka-yoke is a Japanese word for mistake

proofing
Mechanism that prevents a mistake from
being made which is obvious at a glance.

TO ERR IS HUMAN NATURE

BUT
INTELLIGENCE IS ALSO HUMAN
NATURE
SO
NEVER STOP FINDING WAYS OF NOT
MAKING MISTAKES

POKA-YOKE
CAUSES

EFFECTS

DISTRACTION
CONFUSION
LACK OF

PRACTICE
UNCERTAINITY

DEFECTS

INATTENTION
ERROR

(QUALITY)
INSUFFIECIENT
NUMBER
(QUANTITY)
ACCIDENTS
(SAFETY)
DELAY IN WORK

No System of Barriers is
Perfect

No System of Barriers is Perfect

But improvements can be made

POKA-YOKE
A SYSTEM for organizing work
that
Excludes any risk of error
even by the beginner
Allows everyone to operate
without mistake
Prevents error that are about
to occur.

TYPES OF POKA-YOKE
Poka-yoke systems consist of three primary
methods:

1. Contact
2. Counting
3. Motion-Sequence

Each method can be used in a control system or a

warning system.
Each method uses a different process prevention
approach for dealing with irregularities.

1.CONTACT METHOD
Contact method is based on some type of

sensing device which detects abnormalities

in the products shape and dimension and
responds accordingly.
It functions by detecting whether a sensing

device makes contact with a part or object

within the process.

Example
An example of a
contact device using
a limit switch. In
this case the switch
makes contact with

a metal barb
sensing its
presence. If no
contact is made the
process will shut
down.

2. FIXED COUNTING METHOD

Fixed counting method is used in processes

where the same activity is repeated several

times.
This method frequently involves very simple
techniques, such as methods that allow
operators to easily track how often this
activity has been performed

Example

A sensor counts the number of times a

part is used or a process is completed
and releases the part only when the
right count is reached.
In the example to the right a limit
switch is used to detect and count
when the required amount of holes are
drilled. The buzzer sounds alerting the
operator that the appropriate amount
of steps have been taken in the
process.

3.MOTION STEP METHOD

The motion step method is useful for

processes requiring several different activities

performed in sequence by a single operator.
It uses sensors to determine whether a
motion or a step in a process has occurred. If
the step has not occurred or has occurred out
of sequence, the sensor signals a timer or
other device to stop the machine and signal
the operator.

Example
In this example, each step of the machine cycle is wired to an
indicator board and a timer. If each cycle of the machine is not
performed within the required time and sequence, the
indicator light for that step will be turned on and the machine will
stop.

MACHINE

INDICATOR BOARD

EVERYDAY EXAMPLES

3.5 inch diskette

Electronic door locks

Electric Iron

Stove burner

Hotel rooms are equipped with a

room key holder

IMPLEMENTATION

Warning poka-yoke
the operator is alerted when a mistake is about to be
made

Control poka-yoke
the poka-yoke device actually prevents the mistake from
being made

THANK YOU