WHAT IS POKA-YOKE OR MISTAKE-PROOFING AND HOW IT IS DEPLOYED IN THE INDUSTRY

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What is poka-yoke and how it is deployed in the industry

In the TPM implementation process, we come across so many Japanese terms. It is not possible to translate them verbatim, as Japanese connotations are very different from other parts of the world. Poka-yoke is one such term. Poka-yoke is a Japanese term that means “mistake-proofing” or “error-proofing.” The aim of this is to improve the systems and instruments in such a way that there is no chance of human or technical error. It is a concept that aims to design the process or product in such a way that it is impossible or difficult to make a mistake. The term was first introduced by Shigeo Shingo, a Japanese industrial engineer, in the 1960s.

Poka-yoke techniques can be classified into three categories:

Contact Method This method uses a physical device to prevent a mistake. For example, a car key can only be removed from the ignition when the car is in the park, which prevents the driver from leaving the car in gear.
Fixed-Value Method This method sets a limit or a standard for a process or product, and it is designed in such a way that it is impossible to exceed that limit or standard. For example, a vending machine that only accepts exact changes will not allow a customer to make an incorrect payment.
Motion-Step Method This method ensures that a process is completed correctly by requiring the operator to follow a specific sequence of steps. For example, a computer program requires the user to input certain information in a specific order.

Poka-yoke techniques can be applied in various industries, including manufacturing, healthcare, and service. Here are some examples of how poka-yoke is deployed in the industry:

Automotive Industry In the automotive industry, poka-yoke is used to prevent defects in the manufacturing process. For example, the use of jigs and fixtures in the assembly line ensures that each part is placed in the correct position, preventing mistakes from occurring. Additionally, the use of warning lights or alarms in the dashboard of a car alerts the driver to potential problems, such as low tire pressure or a malfunctioning engine. In a railway signaling system, the line clearance to a train is not given unless the other train passes. It is done by providing an interlock in the system.
Healthcare Industry In the healthcare industry, poka-yoke is used to prevent errors in patient care. For example, the use of barcode scanners in medication administration ensures that the right medication is given to the right patient in the right dose. Additionally, surgical instruments are designed in such a way that they can only be used for specific procedures, preventing mistakes from occurring during surgery.
Service Industry In the service industry, poka-yoke is used to improve customer satisfaction and prevent mistakes in service delivery. For example, a restaurant may use color-coded plates to ensure that the correct food is delivered to the correct table. Additionally, self-checkout kiosks in retail stores use poka-yoke techniques to prevent customers from scanning items multiple times or forgetting to scan an item.

Summing it up, poka-yoke is a concept that aims to prevent defects or errors from occurring in a manufacturing or service process. It is deployed in various industries, including automotive, healthcare, and service, to improve quality, increase efficiency, and reduce costs. By using poka-yoke techniques, organizations can improve their processes and products, leading to increased customer satisfaction and profitability.