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Process that helps an equipment operator avoid mistakes

Poka-yoke (ポカヨケ, [poka joke]) is

a Japanese term that means "mistake-proofing" or "error 3️⃣ prevention". It is also

sometimes referred to as a forcing function or a behavior-shaping constraint.

A

poka-yoke is any mechanism in 3️⃣ a process that helps an equipment operator avoid (yokeru)

mistakes (poka) and defects by preventing, correcting, or drawing attention to 3️⃣ human

errors as they occur.[1] The concept was formalized, and the term adopted, by Shigeo

Shingo as part of the 3️⃣ Toyota Production System.[2][3]

Etymology [ edit ]

Poka-yoke was

originally baka-yoke, but as this means "fool-proofing" (or "idiot-proofing") the name

was changed 3️⃣ to the milder poka-yoke.[4] Poka-yoke is derived from poka o yokeru

(ポカを避ける), a term in shogi that means avoiding an 3️⃣ unthinkably bad move.

Usage and

examples [ edit ]

More broadly, the term can refer to any behavior-shaping constraint

designed into a 3️⃣ process to prevent incorrect operation by the user.

A simple poka-yoke

example is demonstrated when a driver of the car equipped 3️⃣ with a manual gearbox must

press on the clutch pedal (a process step, therefore a poka-yoke) prior to starting an

3️⃣ automobile.[5] The interlock serves to prevent unintended movement of the car. Another

example of poka-yoke would be the car equipped 3️⃣ with an automatic transmission, which

has a switch that requires the car to be in "Park" or "Neutral" before the 3️⃣ car can be

started (some automatic transmissions require the brake pedal to be depressed as well).

These serve as behavior-shaping 3️⃣ constraints as the action of "car in Park (or Neutral)"

or "foot depressing the clutch/brake pedal" must be performed before 3️⃣ the car is allowed

to start. The requirement of a depressed brake pedal to shift most of the cars with 3️⃣ an

automatic transmission from "Park" to any other gear is yet another example of a

poka-yoke application. Over time, the 3️⃣ driver's behavior is conformed with the

requirements by repetition and habit.

When automobiles first started shipping with

on-board GPS systems, it 3️⃣ was not uncommon to use a forcing function which prevented the

user from interacting with the GPS (such as entering 3️⃣ in a destination) while the car

was in motion. This ensures that the driver's attention is not distracted by the 3️⃣ GPS.

However, many drivers found this feature irksome, and the forcing function has largely

been abandoned. This reinforces the idea 3️⃣ that forcing functions are not always the best

approach to shaping behavior.

The microwave oven provides another example of a forcing

3️⃣ function.[6] In all modern microwave ovens, it is impossible to start the microwave

while the door is still open. Likewise, 3️⃣ the microwave will shut off automatically if

the door is opened by the user. By forcing the user to close 3️⃣ the microwave door while

it is in use, it becomes impossible for the user to err by leaving the door 3️⃣ open.

Forcing functions are very effective in safety critical situations such as this, but

can cause confusion in more complex 3️⃣ systems that do not inform the user of the error

that has been made.

These forcing functions are being used in 3️⃣ the service industry as

well. Call centers concerned with credit card fraud and friendly fraud are using

agent-assisted automation to 3️⃣ prevent the agent from seeing or hearing the credit card

information so that it cannot be stolen. The customer punches 3️⃣ the information into

their phone keypad, the tones are masked to the agent and are not visible in the

customer 3️⃣ relationship management software.[7]

History [ edit ]

The term poka-yoke was

applied by Shigeo Shingo in the 1960s to industrial processes designed 3️⃣ to prevent human

errors.[1] Shingo redesigned a process in which factory workers, while assembling a

small switch, would often forget 3️⃣ to insert the required spring under one of the switch

buttons. In the redesigned process, the worker would perform the 3️⃣ task in two steps,

first preparing the two required springs and placing them in a placeholder, then

inserting the springs 3️⃣ from the placeholder into the switch. When a spring remained in

the placeholder, the workers knew that they had forgotten 3️⃣ to insert it and could

correct the mistake effortlessly.[8]

Shingo distinguished between the concepts of

inevitable human mistakes and defects in 3️⃣ the production. Defects occur when the

mistakes are allowed to reach the customer. The aim of poka-yoke is to design 3️⃣ the

process so that mistakes can be detected and corrected immediately, eliminating defects

at the source.

Implementation in manufacturing [ edit 3️⃣ ]

Poka-yoke can be implemented at

any step of a manufacturing process where something can go wrong or an error can 3️⃣ be

made.[9] For example, a fixture that holds pieces for processing might be modified to

only allow pieces to be 3️⃣ held in the correct orientation,[10] or a digital counter might

track the number of spot welds on each piece to 3️⃣ ensure that the worker executes the

correct number of welds.[10]

Shingo recognized three types of poka-yoke for detecting

and preventing errors 3️⃣ in a mass production system:[2][9]

The contact method identifies

product defects by testing the product's shape, size, color, or other physical

3️⃣ attributes. The fixed-value (or constant number) method alerts the operator if a

certain number of movements are not made. The 3️⃣ motion-step (or sequence) method

determines whether the prescribed steps of the process have been followed.

Either the

operator is alerted when 3️⃣ a mistake is about to be made, or the poka-yoke device

actually prevents the mistake from being made. In Shingo's 3️⃣ lexicon, the former

implementation would be called a warning poka-yoke, while the latter would be referred

to as a control 3️⃣ poka-yoke.[2]

Shingo argued that errors are inevitable in any

manufacturing process, but that if appropriate poka-yokes are implemented, then

mistakes can 3️⃣ be caught quickly and prevented from resulting in defects. By eliminating

defects at the source, the cost of mistakes within 3️⃣ a company is reduced.[citation

needed]

Benefits of poka-yoke implementation [ edit ]

A typical feature of poka-yoke

solutions is that they don't 3️⃣ let an error in a process happen. Other advantages

include:[11]

Less time spent on training workers;

Elimination of many operations

related to 3️⃣ quality control;

Unburdening of operators from repetitive

operations;

Promotion of the work improvement-oriented approach and actions;

A reduced

number of rejects;

Immediate action when 3️⃣ a problem occurs;

100% built-in quality

control;

Preventing bad products from reaching customers;

Detecting mistakes as they

occur;

Eliminating defects before they occur.

See also 3️⃣ [ edit ]

References [ edit ]

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