Poka-Yoke: Manufacturing Mistake-Proofing

Paper Summary:

This paper examines Poka-Yoke, a Japanese term used to denote a fool-proofing technique that constitutes the core of zero quality control (ZQC). The paper explains that the term is derived from Poka, implying unintentional mistake, and Yoke, meaning avoiding. Normally, this technique is applied in the manufacturing processes, but has extensive uses in offices, order and invoice processing, hospitals and drug dispensing, and maintenance of aircrafts especially with processes that run the risk of causing dangerous in-service breakdown. The paper concludes that, because mistakes can be costly, Poka-Yoke is gaining popularity and is acknowledged as a competitive tool in the production process.

Outline:
Introduction to Poka-Yoke
Poka-Yoke in Manufacturing
Poka-Yoke and Modern Lean Production System
The Growing Relevance of Poka-Yoke

From the Paper:

"Repeated checks are having the closest downstream operation check the work of the earlier operation. It is ensured that each operation carries out production as well as quality inspection. Efficient poka-yoke devices render such an inspection system a reality by lowering the time and cost of inspection to almost zero. Since inspections involve minimal cost, each and every time might be inspected. Given that work-in-process inventories are low, quality feedback used to enhance the process can be provided very rapidly. Self-checks using poka-yoke devices let workers evaluate the quality of their own work. As they check each and every unit produced, operators might be able to find out what conditions underwent changes that led to the previous unit to be defective. This understanding is used to check subsequent defects. Self-checks are chosen to successive checks in cases wherever feasible (A Brief Tutorial on Mistake-Proofing, Poka-Yoke, and ZQC)"

Sample of Sources Used:

• Grout, John R; Downs, Brian T. A brief Tutorial on Mistake-proofing, Poka-Yoke, and ZQC. <http://www.isixsigma.com/offsite.asp?A=Fr&Url=http://www.campbell.berry.edu/faculty/jgrout/tutorial.html>
• Kurtus, Ron. Prevent mistakes with Poka-Yoke. 14 November, 2001. <http://www.school-for-champions.com/tqm/poka-yoke.htm>
• Manivannan, Subramaniam. Error-Proofing enhances quality, Manufacturing Engineering, vol. 137, no. 5, November 2006. pp: 12-15.
• N. A. Poka-Yoke: Human Error. Quality Management & Training Limited. 2007. <http://www.poka-yoke.org.uk/>
• Nersesian, Roy. L. Trends and Tools for Operations Management. Quorum Books. 2000.

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