Mistake Proofing (Poka Yoke)
The goal of mistake-proofing or Poka Yoke is simple: to eliminate mistakes.
In order to eliminate mistakes, processes need to be modified / controlled so that it is impossible to commit mistakes. With mistake-proofing solutions, many repetitive tasks that depend upon the operator skill and memory are built into the process itself. Mistake-proofing frees the time and minds of the workforce to pursue more creative and value-adding activities.
Mistake-proofing also involves a change in the culture of the organization. Organizations must establish a mistake-proofing culture that promotes the belief that it is unacceptable to allow for even a small number of product or service defects.
Zero PPM or 3.4 defects per million opportunities (3.4 DPMOs) can be achieved therough mistake - proofing
There can be Four different effects from mistake-proofing
The following device level controls can be achieved using mistake-proofing, where forced control effect offers highest power of control while sensory alert effect offer least power of control.
Any of these effects can offer two types of control outcomes, namely Prevention Control outcome or Detection control outcome. Thus there are potentially 8 different control outcomes can be dsigned to control a process failure.
4 effects
The efects can be controlled by a response either Automatic and compulsory or Operator dependant and discretionary
Automatic and compulsory
- Forced Control Devices
- Shutdown Devices
Operator dependant and discretionary
3. Warning Devices
4. Sensory Alert Devices
2 Types of control method
- Mistake Prevention Control
- Mistake Detection Control
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