In short: Poka-yoke (mistake-proofing) uses simple devices or process designs that prevent errors or make them immediately visible, so defects are stopped at the source rather than found by inspection.
What are the types of poka-yoke?
- Prevention: the error cannot be made (e.g. connectors that fit only one way)
- Detection: the error is flagged immediately (e.g. sensors, alarms, checklists with interlocks)
Where does poka-yoke work outside manufacturing?
Mandatory form fields, barcode checks for medication, and software validation rules are all examples of mistake-proofing in services.
Key takeaways
- Prevent errors at the source.
- Prefer prevention over detection.
- Simple, low-cost solutions are often best.
Frequently asked questions
Who developed poka-yoke?
Shigeo Shingo, as part of the Toyota Production System.
Is poka-yoke expensive?
Usually not; many devices are simple and low cost.
How do I find opportunities?
Look at recurring human errors in your nonconformity and complaint data.