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TECHNIQUE, METHODOLOGY & DESIGN

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Indian Journal of Engineering ANALYSIS
An International Journal
ISSN 2319 – 7757 EISSN 2319 –7765
© 2016 Discovery Publication. All Rights Reserved

Poka-yoke technique, methodology & design

Publication History
Received: 29 April 2016
Accepted: 26 May 2016
Published: 1 July 2016

Citation
Rajan kumar, Dwivedi RK, Ajay Verma. Poka-yoke technique, methodology & design. Indian Journal of Engineering, 2016,
13(33), 362-370

Page | 362
 POKA-YOKE TECHNIQUE, METHODOLOGY & DESIGN

Rajan kumar1, R.K.Dwivedi2, Ajay Verma3

1
Assistant Professor, Mechanical Engineering, TIT Group, Bhopal, Madhya Pradesh, India
2
Associate Professor, Mechanical Engineering, MANIT, Bhopal, Madhya Pradesh, India
3
Assistant Professor, Mechanical Engineering, MANIT, Bhopal, Madhya Pradesh, India

ABSTRACT: Poka-yoke is a concept in total quality management which is related to restricting errors at
cradle itself. It deals with "error proofing", fail-safing or "mistake-proofing". A poka-yoke is idea generation or
mechanism development in a total productive management process that helps operator to avoid (yokeru)
mistakes (poka). The concept Poka-yoke was produced, and established by Japanese engineer Shigeo Shingo for
the Toyota Production System. The Poka-Yoke is an innovative technique for to keep away human error at
work. The technique starts by analysing the process for potential problems, categorising parts by the
characteristics of dimension, shape & size & weight, detecting process deviation from nominal procedures and
norms. The original idea overduepoka-yoke is to respect the intellect of workers. Poka-yokes are for freeing
worker’s time and mind to pursue more creative and value adding activities.

Key Words; Pokayoke, poka yoke technique, total quality management

I. INTRODUCTION
In today’s competitive world any organisation has to manufacture high quality, defect free products at optimum
cost. The new culture of the total quality management, total productive management into the manufacturing as
well as service sector gave birth to new ways to improve quality of products. By using various tools of TQM
like KAIZEN, 6 sigma, JIT, JIDCO, POKA YOKE, FMS & etc. other technique. organisation is intended to
develop qualityculture.[2,6] The paper is intended to focus basic concept of poka yoke, types of poka yoke
system, ways to achieve simple poka yoke mechanism. It is also covers practical study work done by various

II. WHAT IS POKA YOKE?

Poke-yoke (Mistake proofing) is a Japanese improvement strategy for mistake-proofing to prevent defects (or
Nonconformities) from arising during manufacturing processes. Poka-yoke is a preventive action that focuses on
identifying and eliminating the special causes of variation in manufacturing processes, which inevitably lead to
product defects or nonconformities. This concept was initially called Idiot Proofing but it was understood that
this name may heart workers so term Mistake Proofing was coined by Shigeo Shingo. [1, 5]Poka-yoke gives a
strategy and policy for preventing defects at the source. Poka-yoke solutions are not only the cost-effective but
also easy to understand and apply. Mistake proofing is one of the important tools to add to any organization’s
Continuous improvement. In short poka-yoke is a continual improvement strategy that offers a way to move the
QMS (quality management system) towards a higher level of performance.[2]The poka-yoke(mistake proofing)
concept was generated in the mid-1960s by Shigeo Shingo who is Japanese industrial engineer. Shingo was
working for the Toyota and other Japanese companies, where he developed entire Manufacturing systems
focused on achieving zero defects in production and gave birth to this revolutionary work. The basic concept
behind poka-yoke(mistake proofing) is that it is not acceptable and allowed to produce even a small amount of
nonconforming product. [1,2]To stay in market and to become a whole world-class competitor, an organization
must go with new strategy and technology along with side by side practice of producing zero defects. Poka-yoke
methods are the easy and simple concepts for achieving this goal and are a key component of the continual
improvement strategy in many leading Japanese companies on this moment. Poka-yoke (fool proofing) is one of
the presentations of “good kaizen”, or superior continual improvement because of its preventive nature. Apoka-
yoke device or solution is apply any mechanism or idea that either avoids the mistake from being made or
makes the mistake easily identify at a glance. The ability to find mistakes at a glance is important because, as
Shingo states, "The causes of defect lie in workers errors, and defects are the results of neglecting those errors. It
follows that mistakes will not turn into defects if worker
errors are discovered and eliminated beforehand"[Shingo 1986, p.50].[4] He also adds to this that "Defects arise
because errors are made; the two have a cause-and-effect relationship. ... Yet errors will not turn into defects if

Page | 363
feedback and action take place at the error stage"[Shingo, 1986, p. 82].[4]During actual manufacturing of any
product there are too many very simple and monotonous steps which are carried out by operators. These are
monotonous work operations result in to mental fatigue and lack of interest in work which ultimately causes
silly mistakes of operators and we know that human is prone to errors even though he doesn’t want it. [5]To
avoid these simple mistakes by poka-yoke concept play important role. By implementing some simple solutions
we can avoid mistakes. The long term achievement of poka- yoke gives output of saving time and we release the
work pressure on mind of worker. We can use creativity and innovative skills of workers for more creative
operations instead of increasing pressure for monotonous activities This involvement of everyone in
organisation is basic need to rise roots of quality culture in the organisation.

III.COMMON DEVICE USED IN POKA-YOKE SYSTEMS

1. Guide pin
2. Blinking light and Alarms
3. Limit Switches
4. Proximity switches(sensor)

1. Guide pin: Guide pins are often used as a means of ensuring the accuracy with which machined parts
are stacked on top of one another. They may also be used as a means of correctly aligning one
component of a two-part system with the other. The pin may actually come in the form of a bolt with a
tapered end or even in the shape of a bullet with the corresponding piece containing metal or
plasticized grommets at every contact point. The grommets would allow the guide pins to penetrate the
secondary component in order to ensure the accurate configuration of the two parts being put together.

2. Blinking light and alarm: modular design with sturdy housing for all indoor and outdoor
applications in tough conditions wherever machine status needs to be displayed and warning signals
given

3. Limit Switch: A limit switch is an electromechanical device that consists of a actuator mechanically
linked with a set of contacts. When any object comes into contact with the actuator, the device operates
the contacts to make or break an electrical connection. Limit switches are used in a different type of
applications and environments because of their ruggedness, ease of installation, and reliability of
operation. Limit Switch can determine the presence / absence, passing, positioning, and end of travel of
an object. Limit switch were first used to define the limit of travel of an object; hence the name "Limit
Switch".
4. Sensor: A sensor is a transducer whose purpose is to sense (that is, to detect) some characteristic of its
environs. It detects events or changes in quantities and provides a corresponding output, generally as an
electrical or optical signal; for example, a thermocouple converts temperature to an output voltage. But
a mercury-in-glass thermometer is also a sensor;
Sensing devise are traditionally used in poka-yoke
i. Physical contact device
ii. Energy sensing device

(a) Photo electric Sensor

The transmitter and receiver of the thru-beam sensor and housed in different cases that are separated from each
other the Emitter(E) Transmits directly to the receiver(R). If object(O) interrupt the light beam, the receiver
voltage drop and the switching function is initiated. The thru-beam sensor are used to monitor production and
packing lines to measure full state in transparent container or as a safety measure for door and hazardous area.

Page | 364
 Fig-1; sensing object interrupt the light

(b) Vibration sensor

Despite the advances made in vibration monitoring and analysis equipment, the selection of sensors and the way
they are mounted on a machine remain critical factors in determining the success of any monitoring program.
Money saved by installing inferior sensors is not a prudent investment since the information provided about the
machine of interest often is not accurate or reliable. Poor quality sensors can easily give misleading data or, in
some cases, cause a critical machine condition to be completely overlooked.

Fig-2-Vibration sensor

IV. Need of Mistake Proofing

When any organization decides to implement the lean manufacturing then one of the objective is to reduce scrap
because no one is interested to compensate extra inventory on account of scrap. As per philosophy of lean
manufacturing it focuses on speed of production and productivity also. In order to follow this concept of speed
we should prevail against defects and rework. To the increase profit percentage the cost pressures always
become headache for top management so they never accept continued mistakes like scrap, rework, lateness etc.
out of tolerance instead they are aiming to achieve value of zero in this segment. When customers of any
company buys product they rightfully expect defect free products and conventional 100% inspection or
statistical process control don’t insure 100% defect-free products (zero defect). [1]Hence we are going to root
cause of any problem and avoiding it which gives us defect free product. In the above discussion concludes that
to get defect free products one should go with the concept of PokaYoke. Below graph plotted between
cost/defects

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 Fig-3;cost& zero defects relation

V. TYPES OF POKA YOKE

The Poka-Yoke is an innovative technique for to keep away human error at work. A defect or imperfection
exists in either of two states; the defect either has already occurred in that case calling for defect detection, or is
about to occur in that case calling for defects prediction. The technique starts by analysing the process for
potential problems, identifying parts by the characteristics of dimension, shape & size and weight, detecting
process deviation from nominal procedures and norms. Depending on the basic functionality Poka-yoke has
three types
1. Shutdown Poka yoke
2. Control Poka yoke
3. Warning Poka yoke

5.1 Shutdown (Prevention) Method

In shut down i.e. prevention method Poka-yoke devices checks critical process parameters and shut down the
process when a situation moves out of the tolerance zone, it is indicates of a defective product has either been
produced or is about to be produced. [2]That is well known note that prevention is always better than cure. By
implementing shutdown method we can assure about 100% defect free products.[1] It has 0 % chances to
produced defective products, up to this level we can reliance on it.[2] E.g. Use of fuse in the electric circuit.
Whenthereisan short circuit then fuse is operated and cut down the supply of electricity resulting in avoiding any
further accidents.

5.2 Control method

In control method Poka-yoke devices are regulatory in working which are installed on process equipment and/or
Work pieces which make it impossible to produce defects and/or to flow a nonconforming product to the next
process.[2] As like shut down is an method control method gives 100% defect free products. [1]The control
make certainty that if there is any defect, it is not coming outside the production line and does not reach to the
customer. E.g. To avoid any wrong job loading in reverse direction on machine we can provide work rest for the
job which will avoidwrong job loading.
5.3 Warning (Alert) method
This is the method which makes the operator conscious about something is going wrong. The
Mechanism or simple idea is generated in such a way that Poka-yoke devices indicate or shows to a worker that
a defect has been produced. When operators get such warning then he must immediately interfere the process to
correct the process (es) responsible for causing the defect. In case of irresponsible behaviour of operator
irrespective of getting warning notice the next products will continue the same defect and produce
nonconforming products. [2] In short again warning (alert) method depends on human nature and behaviour. It
is concluded that alert method gives 30% of the guarantee of good products. Actually warning method tells
about existence of defect but does not assure and does not produce 100% quality. [1]Thecommon warning
method are use of blinking light and use of beeping sound as alarm alert. e.g. Beeping sound or flashing of light
in ATM machine after removing ATM card from machine to warn operator that he is safe and ensure that card is
not in machine. Once top management decides to implement TPM culture in organization then to compensate
for defect freeproducts successfully one should follow the following methodology
VI. Methodology of poka yoke
1. Identify Problem
2. Observation at workstation
3. Brainstorming for idea
4. Select best idea
5. Implementation Plan

Page | 366
 6. Implement
7. Monitor and sign off

Identify Problem

Observation at workstation

Brainstorming for idea

Select best idea

Implementation Plan

Implement

Monitor and sign off

Fig-4; Methodology

6.1Step 1 Identify problem

In this stage the complaints coming from the customers (Both internal and external customer) are collected. The
principle of standard is determined by considering various criteria’s like number of complaints from the
customer& PDI( pre dispatch classify), the quantity of defects detected by quality control, materiality defects
(their impact on the customer, costs, implemented process) and then data is collected broadly. As per analysis all
results of the collected data company plans for developing poka yoke system for the selected problem. In this
way in first stage the problem is selected,

6.2 Step 2 Observation at work stations

In this step the actual on site study of the problem is carried out. The causes behind the problem are sort out by
using fishbone diagram (fishbone diagram is cause and effect diagram given by Japans management guru
Ishikawa).The causes may be related to man skill, machine, material or method accordingly the complete sorting
is carried out.
4.3 Step 3 Brainstorming for Idea
This is a technique to capture all creativity and skills of employee’s .In brainstorming session the problem under
study is put forward to committee. Then study problem given by all members and give various solutions to
avoid that defect. As each person has one uniqueness this step concludes with various alternative solutions for
same problem

.6.4 Step 4 Select best ideas

After getting all various alternative solutions it is time to select best one out of all collected solutions. Criteria
for selection may be cost, problem create after istallation,time required, changes in existing system, opportunity
to develop new solutions, simplicity in operation etc. By referring all selection criteria’s committee concludes
With one best solution.

6.5 Step 5 Implementation plan and implementation

This step is concerned with implementation planning& installation. It deals with material requirement,
processing the material and finally manufactured mechanism is implemented at actual working site.

6.6 Step 6 Monitoring and sign off

The produced products are checked for defects under study also the performance of poka yoke system is also
monitored and project is shut downed.

Page | 367
 Fig-5 ;Poka-Yoke System design

VII Methods Of Obtaining Poka Yoke

Poka yoke ideas are simple but creative in operation and generation. According to Shingo [Shingo,1986, p.71],
"Defects will never be reduced if the workers involved do not modify operating methods when
defects occur." [4]
Following are some of the simple ideas (hints) to avoid mistakes: - [5]
1) Using Shapes and Colors
2) Software Warnings and Reminders
3) Using Dialogue Boxes and Software Checks
4) Using Switches and Automatic Braking
5) Using Checklists
6) Visual Prevention Methods
7) Using Lights, Sounds, Signs and Barriers Etc.

VIII Challenges and Limitations ofPoka Yoke

As per up till discussion in the paper it seems that poka yoke is one of the best tool in total quality
management but we have to think about the obstacles and challenges against poka yoke.
1. Practical implementation of the mechanism or solution is not possible.
2. Process parameters don’t allow changing the existing system.
3. Sometimes the poka yoke is not cost effective.
4. Interdepartmental relations between production and quality depth are not good so each one think that I
don’thave to do anything with that issue.
5. Now also we are depending on statistical process control.
6. Expert advice is needed for new creative and challenging tasks .It may happen that experts are not
availablewith small scale industries and expert advice is not economical for their financial health.

IX Examples ofPoka Yoke

1. Spindle of CNC machine starts only after closing the safety door. If door is open then machine will
not run.It is shut down poka yoke to avoid accidents.
2. The guide pins are used in stamping dies for correct alignment of upper and lower portion. If there isimproper
matching assembly of dies will not take place. It is shut down poka yoke.
3. If we want to close any file in operating software (e.g. Microsoft Word) it asks for save it or cancel dialogue
box. This is warning system against by mistake closing of file. It is warning poka yoke.[5]
4. To avoid parallax error in reading the measuring instrument small mirror is placed below the moving pointer.
By referring pointer and its mirror image we can take proper reading. It is warning poka yoke.
5. The socket for USB on the computer is designed in such a way that we can’t connect pen drive or any
corresponding pin in opposite or wrong way. It is control poka yoke system.[5]

Page | 368
6. Pressure relief valves are used in hydraulic circuit to prevent damage to system due to high pressure. In case
of high pressure the excess oil bleed off through check valve to the reservoir. It is control poka yoke system.
7. Check list is used to confirm that all subcomponents in assembly are assembled. It is control poka yoke
system.[2]

X CONCLUSION
To err is human nature so we can’t blame human being for each and every mistake. As like err, Intelligence is
also human nature so we can dominate preceding nature by next nature. Poka yoke is just a face of that
intelligence. We can avoid all the mistakes at the source itself by using above mentioned methodology. About
mistake proofing we can say that it is a system for organizing work that eliminates any chances of error by new
user is also. It also allow user to function without mistake or prevent error that are about to occur. In order to
implement quality management system successfully each activity should aim towards excellence. Poka yoke is
one of the most important tools in TQM (total quality management). Efficaciouspoka yoke results in increased
productivity with minimum waste (waste due to rework, scraps) because we are sure about the quality of
product, as mistakes are blocked at source itself. There may be any practical limitations in poka yoke but we
have to overcome all that for achieving the aim of product manufacturing “Fault, Waste & Delay” all of them
zero. In one decisionPoka-yoke(Mistake proofing) is launching preventive actions for systematic movement on
the success ladder of QMS with higher level of performance and productivity of system with high quality
products at minimum cost.

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