{"id":15776,"date":"2014-11-03T18:32:58","date_gmt":"2014-11-03T23:32:58","guid":{"rendered":"https:\/\/staging.opexlearning.com\/resources\/?page_id=15776"},"modified":"2020-09-06T19:28:10","modified_gmt":"2020-09-07T00:28:10","slug":"what-is-poka-yoke","status":"publish","type":"page","link":"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-poka-yoke\/","title":{"rendered":"What is Poka Yoke"},"content":{"rendered":"<div class=\"a296a24fa2fc69ef5487857f02f111e8\" data-index=\"9\" style=\"float: none; margin:10px 0 10px 0; text-align:center;\">\n<script async src=\"\/\/pagead2.googlesyndication.com\/pagead\/js\/adsbygoogle.js\"><\/script>\r\n<!-- Single Post readerboard -->\r\n<ins class=\"adsbygoogle\"\r\n     style=\"display:inline-block;width:728px;height:90px\"\r\n     data-ad-client=\"ca-pub-8207522353004717\"\r\n     data-ad-slot=\"1144967431\"><\/ins>\r\n<script>\r\n(adsbygoogle = window.adsbygoogle || []).push({});\r\n<\/script>\n<\/div>\n<p>What is Poka Yoke is a common question. As is true with many Japanese terms, they carry a level of mystery and intrigue that is not really merited. You see, in North America, <a title=\"lesson in poka yoke from a coffee cup\" href=\"https:\/\/staging.opexlearning.com\/resources\/a-coffee-cup-taught-me-about-poka-yoke-human-errors\/12986\/\">Poka-Yoke<\/a> is more commonly known as <a title=\"definition of error proof and mistake proof\" href=\"https:\/\/staging.opexlearning.com\/resources\/everyday-poka-yoke-door-knob-safety\/2512\/\">mistake-proof<\/a> or error-proof.<\/p>\n<p>But even that doesn&#8217;t really carry the full meaning of the Japanese term. There&#8217;s a little bit more.<\/p>\n<p>Idiot-proof would be a more accurate term that is in the spirit of what the Japanese Poka-Yoke means, but not in a mean way. What I mean is that no matter who the person is, what\u00a0their\u00a0physical or cognitive ability, can they perform the activity and process and there are enough robust prevention measures such that the person doesn&#8217;t make a mistake?<\/p>\n<p>That&#8217;s what Poka-Yoke really means.<\/p>\n<div align=\"center\">\r\n<table border=\"1\" cellpadding=\"5\">\r\n<tbody>\r\n<tr>\r\n<td style=\"text-align: center;\" colspan=\"2\"><strong>Other Poka-Yoke Examples and Articles<\/strong><\/td>\r\n<\/tr>\r\n<tr>\r\n<td>\r\n<ul>\r\n\t<li><a title=\"reduce what you eat with this nifty trick from facebook cafeteria\" href=\"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-overeating-overweight-lose-weight\/10207\/\">Limit Food Consumption Poka Yoke<\/a><\/li>\r\n\t<li><a title=\"coffee cup has serious problems bro\" href=\"https:\/\/staging.opexlearning.com\/resources\/a-coffee-cup-taught-me-about-poka-yoke-human-errors\/12986\/\">Why This Coffee Cup has Issues<\/a><\/li>\r\n\t<li><a title=\"how to prevent errors through public humiliation\" href=\"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-examples-prevent-error-embarrasment\/9511\/\">How to Prevent Errors Through Humiliation<\/a><\/li>\r\n\t<li><a title=\"can't skateboard on this park bench\" href=\"https:\/\/staging.opexlearning.com\/resources\/no-skateboarding-sign-a-poka-yoke-approach\/9448\/\">No Skateboarding Here<\/a><\/li>\r\n\t<li><a title=\"how to make sure the toilet seat cover is always down\" href=\"https:\/\/staging.opexlearning.com\/resources\/carnival-cruise-reviews-toilet-poka-yoke\/9398\/\">Toilet Seat Poka Yoke<\/a><\/li>\r\n\t<li><a title=\"atm machine creates problems\" href=\"https:\/\/staging.opexlearning.com\/resources\/to-err-is-human-atm-machine-poka-yoke\/9320\/\">This ATM Sucks and Causes Problems<\/a><\/li>\r\n\t<li><a title=\"method for checking for errors\" href=\"https:\/\/staging.opexlearning.com\/resources\/how-to-check-for-errors\/9292\/\">How to Check for Errors<\/a><\/li>\r\n\t<li><a title=\"error proof dyslexia through this font\" href=\"https:\/\/staging.opexlearning.com\/resources\/dyslexia-treatment-poka-yoke-innovation-standard-work\/9251\/\">How to Error Proof Dyslexia<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<td>\r\n<ul>\r\n\t<li><a title=\"error proof your baby stroller\" href=\"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-baby-stroller-fail\/7242\/\">Why this Baby Stroller Will Hurt Your Child<\/a><\/li>\r\n\t<li><a title=\"door knob safety poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/everyday-poka-yoke-door-knob-safety\/2512\/\">Can Your Child Open the Door Knob?<\/a><\/li>\r\n\t<li><a title=\"prevent theft through this simple poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/everyday-poka-yoke-preventing-theft\/1993\/\">Prevent Theft Poka Yoke<\/a><\/li>\r\n\t<li><a title=\"how to prevent prescription drug abuse - one company's approach\" href=\"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-pharmaceuticals\/1424\/\">Prescription Drug Abuse Error Proofing<\/a><\/li>\r\n\t<li><a title=\"zero defects via poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/cost-of-poor-quality-poka-yoke\/451\/\">Can Poka Yoke Help us Reach Zero Defects?<\/a><\/li>\r\n\t<li><a title=\"eye protection during war poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/root-cause-genchi-genbutsu-design-thinking\/439\/\">Poka Yoke Example of Eye Protection During War<\/a><\/li>\r\n\t<li><a title=\"system design poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-system-design-how-to-mistake-proof-your-processes\/9131\/\">Poka Yoke System Design Ideas<\/a><\/li>\r\n\t<li><a title=\"be careful with that forklift\" href=\"https:\/\/staging.opexlearning.com\/resources\/forklift-and-conveyor-safety\/8484\/\">Conveyor Safety via Poka Yoke<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/div>\r\n<BR>\n<p>Below are the other elements of the Toyota Production System.<\/p>\n<div align=\"center\">\r\n<table cellpadding=\"0\" style=\"width: 819px;\">\r\n<tbody>\r\n<tr>\r\n<td style=\"width: 228px;\">\r\n<ul>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-lean\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-lean\/', 'What is Lean?');\" title=\"what is lean manufacturing or lean management?\">What is Lean?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-heijunka\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-heijunka\/', 'What is Heijunka?');\" title=\"what is heijunka in lean manufacturing\">What is Heijunka?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-andon-in-the-toyota-production-system\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-andon-in-the-toyota-production-system\/', 'What is Andon cord?');\" title=\"what is andon in lean manufacturing and the toyota production system\">What is Andon cord?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-poka-yoke\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-poka-yoke\/', 'What is Poka Yoke?');\" title=\"define poka yoke\">What is Poka Yoke?<\/a><\/li>\r\n<li><a href=\"\/?s=kaizen\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/?s=kaizen', 'What is Kaizen?');\" title=\"what is kaizen in lean manufacturing and the toyota production system\">What is Kaizen?<\/a><\/li>\r\n<li><a href=\"\/resources\/batch-and-queue-or-single-piece-flow\/270\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/batch-and-queue-or-single-piece-flow\/270\/', 'What is One Piece Flow?');\" title=\"what is one piece flow, single piece flow in lean manufacturing\">What is One Piece Flow?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-kanban\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-kanban\/', 'What is Kanban?');\" title=\"what is kanban in lean manufacturing\">What is Kanban?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-push-vs-pull-strategy\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-push-vs-pull-strategy\/', 'What is Pull versus Push?');\" title=\"what is push vs pull strategy?\">What is Pull versus Push?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-just-in-time-manufacturing\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-just-in-time-manufacturing\/', 'What is Just in Time?');\" title=\"what is just in time manufacturing in lean production\">What is Just in Time?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-smed-and-quick-changeover\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-smed-and-quick-changeover\/', 'What is SMED?');\" title=\"what is smed, single minute exchange of dies, and quick changeover in lean manufacturing\">What is SMED?<\/a><\/li>\r\n<li><a href=\"\/resources\/the-toyota-a3-report\/363\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/the-toyota-a3-report\/363\/', 'What is a Toyota A3 Report?');\" title=\"what is toyota a3 report in lean manufacturing?\">What is a Toyota A3 Report?<\/a><\/li>\r\n<li><a href=\"\/resources\/5s\/180\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/5s\/180\/', 'What is 5S?');\" title=\"what is 5S in lean manufacturing and the toyota production system\">What is 5S?<\/a><\/li>\r\n<li><a href=\"\/resources\/manage-for-daily-improvement-lean-manufacturing-system\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/manage-for-daily-improvement-lean-manufacturing-system\/', 'What is Shop Floor Management?');\" title=\"what is lean shop floor management all about?\">What is Shop Floor<br \/>Management?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-kata-process-improvement\/22073\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/what-is-kata-process-improvement\/22073\/', 'What is Kata?');\" title=\"What is Improvement Kata?\">What is Kata?<\/a><\/li>\r\n<li><a href=\"\/resources\/the-theory-of-constraints-the-fundamentals\/2632\/\">What is the Theory of Constraints (TOC)?<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<td style=\"width: 337px;\">\r\n<p style=\"text-align: center;\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-15757 size-full\" src=\"https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2014\/11\/toyota-house-production-system-lean.gif\" alt=\"the toyota house, lean manufacturing\" width=\"400\" height=\"379\" \/><\/p>\r\n<\/td>\r\n<td style=\"width: 254px;\">\r\n<ul>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-lean-leadership\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-lean-leadership\/', 'What is Lean Leadership?');\" title=\"what does lean leadership mean?\">What is Lean Leadership?<\/a><\/li>\r\n<li><a href=\"\/resources\/respect-for-people-principle-lean-management\/14553\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/respect-for-people-principle-lean-management\/14553\/', 'What is Respect for People?');\" title=\"what is respect for people in lean manufacturing\">What is Respect for People?<\/a><\/li>\r\n<li><a href=\"\/resources\/root-cause-analysis\/172\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/root-cause-analysis\/172\/', 'What is the 5 Whys?');\" title=\"what are the 5 whys and root cause analysis in lean manufacturing\">What is the 5 Whys?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-takt-time\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-takt-time\/', 'What is Takt Time?');\" title=\"What is Takt Time in the Toyota Production System?\">What is Takt Time?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-gemba-and-gemba-walk\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-gemba-and-gemba-walk\/', 'What is Gemba?');\" title=\"what is gemba? what is a gemba walk?\">What is Gemba?<\/a><\/li>\r\n<li><a href=\"\/resources\/genchi-genbutsu-go-and-see-part-1\/2896\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/genchi-genbutsu-go-and-see-part-1\/2896\/', 'What is Genchi Genbutsu?');\" title=\"genchi genbutsu, go and see, lean manufacturing\">What is Genchi Genbutsu?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-standard-work\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-standard-work\/', 'What is Standard Work?');\" title=\"what is standard work or standardized work in the toyota production system?\">What is Standard Work?<\/a><\/li>\r\n<li><a href=\"\/resources\/pdca-cycle-or-pdsa-cycle-which-is-right\/13653\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/pdca-cycle-or-pdsa-cycle-which-is-right\/13653\/', 'What is Plan-Do-Check-Act?');\" title=\"what is PDCA in lean manufacturing and the toyota production system\">What is Plan-Do-Check-Act?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-value-stream-mapping\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-value-stream-mapping\/', 'What is Value Stream Mapping?');\" title=\"what is value stream mapping and its benefits\">What is Value Stream Mapping?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-visual-management\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-visual-management\/', 'What is Visual Management?');\" title=\"what is visual management in lean manufacturing\">What is Visual Management?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-mura-muri-muda\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-mura-muri-muda\/', 'What is Mura, Muri, Muda?');\" title=\"what is mura, muri, muda in toyota production system?\">What is Mura, Muri, Muda?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-jidoka\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-jidoka\/', 'What is Jidoka?');\" title=\"what is jidoka in lean manufacturing\">What is Jidoka?<\/a><\/li>\r\n<li><a href=\"\/resources\/about-peter-abilla\/what-is-hoshin-kanri-in-lean-manufacturing\/\" onclick=\"__gaTracker('send', 'event', 'outbound-article', '\/about-peter-abilla\/what-is-hoshin-kanri-in-lean-manufacturing\/', 'What is Hoshin Kanri?');\" title=\"what is hoshin kanri in lean manufacturing\">What is Hoshin Kanri?<\/a><\/li>\r\n<li><a href=\"\/resources\/?s=lean+startup\">What is Lean Startup?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-the-role-of-the-waterspider-in-lean-manufacturing\/22565\/\">What is a Water Spider?<\/a><\/li>\r\n<li><a href=\"\/resources\/what-is-cellular-manufacturing\/23483\/\">What is Cellular Manufacturing?<\/a><\/li>\r\n<\/ul>\r\n<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/div>\n<h2>Poka-Yoke and Zero Defects<\/h2>\n<p><DIV style=\"padding: 2px; margin: 1em 1.5em 1em 0.5em; background: #FFFFA0 none repeat scroll 0% 0%; border: solid; border-width: thin; border-color: #AE9F44; display: block; float: right; width: 20em;\"><DIV style=\"padding: 5px; color: #000000; font-weight: bold; font-size: 9pt;\">Idiot Proof? Error Proof? Mistake Proof?<\/DIV><DIV style=\"background: #FFFFFF; padding: 0.5em; color: #0062A8;\">Often times, I&#8217;ve heard of companies that have set-up new processes or new design, they bring in people unfamiliar with the process and ask them to perform a task. Part of the goal is to identify usability; the other is to make sure the process is robust enough that a new person is prevented from making a mistake.<\/DIV><\/DIV><\/p>\n<p>In terms of identifying defects, eliminating defects, and preventing defects &#8211; the former two have a cost. While preventing defects have some costs, it is the only true way any firm can approach zero defects &#8211; that is by preventing defects all-together.<\/p>\n<p>In other words, the costs grow exponentially as there are fewer and fewer defects, but Poka-Yoke allows us to reach that by preventing defects in the first place.<\/p>\n<h2>Poka-Yoke and Role in Lean<\/h2>\n<p>Poka-Yoke is an approach that can be taken as a <em>countermeasure<\/em> to known and verified root causes. In other words, once the root causes are known through root cause analysis and the 5 Whys, then Poka-Yoke can be an applied countermeasure to make sure the error doesn&#8217;t happen again. So, think of this structure and how Poka-Yoke fits in the larger framework of Lean:<\/p>\n<ul>\n<li>Defect: My 1 year old\u00a0keeps getting up during dinner and disrupts family dinner time.<\/li>\n<li>Root Cause: My 1 year old has free reign over everything.<\/li>\n<li>Countermeasure: Prevent my 1 year old from having free reign. To do that, I can get a baby seat with a seat belt appropriate for a 1 year old.<\/li>\n<\/ul>\n<p>This is just a simple example, but you get the point.<\/p>\n<!--CusAds0-->\n<div style=\"font-size: 0px; height: 0px; line-height: 0px; margin: 0; padding: 0; clear: both;\"><\/div>","protected":false},"excerpt":{"rendered":"<p>What is Poka Yoke is a common question. As is true with many Japanese terms, they carry a level of mystery and intrigue that is not really merited. You see, in North America, Poka-Yoke is more commonly known as mistake-proof or error-proof. But even that doesn&#8217;t really carry the full meaning of the Japanese term. [&hellip;]<\/p>\n","protected":false},"author":12327,"featured_media":0,"parent":2,"menu_order":0,"comment_status":"open","ping_status":"closed","template":"","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v23.0 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>What is Poka Yoke<\/title>\n<meta name=\"description\" content=\"What is Poka Yoke is a common questions that this introductory article aims to answer. In it will be links detailed answers and examples\" \/>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"What is Poka Yoke\" \/>\n<meta property=\"og:description\" content=\"What is Poka Yoke is a common questions that this introductory article aims to answer. In it will be links detailed answers and examples\" \/>\n<meta property=\"og:url\" content=\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-poka-yoke\/\" \/>\n<meta property=\"og:site_name\" content=\"OpEx Learning\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/get.shmula\" \/>\n<meta property=\"article:modified_time\" content=\"2020-09-07T00:28:10+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/staging.opexlearning.com\/resources\/wp-content\/uploads\/2016\/12\/Shmula-KanbanCody-Logo.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"910\" \/>\n\t<meta property=\"og:image:height\" content=\"309\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:site\" content=\"@shmula\" \/>\n<meta name=\"twitter:label1\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-poka-yoke\/\",\"url\":\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-poka-yoke\/\",\"name\":\"What is Poka Yoke\",\"isPartOf\":{\"@id\":\"https:\/\/staging.opexlearning.com\/resources\/#website\"},\"datePublished\":\"2014-11-03T23:32:58+00:00\",\"dateModified\":\"2020-09-07T00:28:10+00:00\",\"description\":\"What is Poka Yoke is a common questions that this introductory article aims to answer. 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