Poka Yoke

• It is also called as error proofing.
• Two words “Error” & “Proofing” says it all. It’s all about ensuring the mistake doesn’t happen.
• It is a quality control technique developed by Shigeo Shingo implemented at Toyota as a part of Toyota Production System (TPS).

• It aims to prevent defects in any process.
• It requires no formal training.
• Best way to error proof the activity is by identifying Mistake proofing or Preventive actions

• Alarm sounds at an ATM machine indicating the customer should retrieve their debit card after their transactions

• If PIN entered incorrectly, the transaction doesn’t happen.

• Debit/Credit card can be inserted in 4 ways into ATM machine, while only one is proper. The ATM software inspects it and returns the card.

Points to ponder while implementing Error proofing Poka-Yoke

• Error proofing is essential if the severity of process failure is high
• The type of error proofing must be chosen based on the severity and occurrence of defects
• First, two error-proofing detections and inspection do not guarantee 100% errorproofing, and still, there is a risk of failure
• Always choose cost-effective error-proofing solutions. In the case of low severity, the return on investment should drive error proofing.
• Prevention is the best way to error-proof, but many time might be expensive.