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Poka Yoke for Mistake Proofing 

Implement Mistake Proofing to Reduce Errors, Defects, and Customer Complaints

PokaYoke

What Is Mistake-Proofing

Mistake Proofing methods are techniques used to prevent failures by early detection and corrective action. The main purpose is to reduce defects from reaching the next process and by subsequent controls to prevent defects from reaching the customers.

It is widely used by Toyota Production System in controlling the quality of manufacturing to the highest yield level. The principles and philosophy as taught by Shigeo Shingo are the primary way for reducing human mistakes, tooling errors machine mechanical problems and processing errors and computational errors that often lead to defective production and much waste.

 

How Mistake-Proofing Reduces Errors And Defects

Mistake Proofing Methods eliminate mistakes and errors by mistake-proofing the process by use of different Poka Yoke controls.
Level 1: Eliminate Mistakes
Level 2: Eliminate Errors
Level 3: Eliminate Defects
Level 4: Zero Defects
Level 5: System Control

 

How To Implement Poka Yoke System In The Workplace

Poka Yoke system is a conceptual application of preventing defects at the workplace. It is important to make the operators understand what they can do to prevent mistakes and errors from arising at their own workplace which in some way differs from the operators’ step by step instruction to comply with the work instruction. In Poka Yoke, the process is designed so that mistakes can be prevented before the process is performed. It is also designed to detect and immediately correct or issue warning for intervention to correct the situation. Accordingly, all the above actions must be taken at the source or at the point of actual work and at the earliest time.

 

Why Poka Yoke Training Is Important

There are innumerable benefits associated with Poka Yoke where employees are trained to put the techniques into practice, including:

1. Ease of assembly
2. Elimination of motion waste
3. Getting it right the first time and every time
4. No mix-up of parts
5. Early detection of errors
6. Self-correction of errors
7. Safety in processing
8. Elimination of hazards
9. Prevention of accidents 10. Prevention of defective processing
11. Elimination of over-production
12. Automatic removal of contamination
13. Ease of setting control
14. Minimizing inspection errors
15. Lowering the cost of quality control
16. Eliminating application errors
17. Improving BOM control
18. Reducing customer complaints

 

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