{"id":9131,"date":"2011-08-23T05:41:06","date_gmt":"2011-08-23T11:41:06","guid":{"rendered":"https:\/\/staging.opexlearning.com\/resources\/?p=9131"},"modified":"2016-12-25T01:13:34","modified_gmt":"2016-12-25T06:13:34","slug":"poka-yoke-system-design-how-to-mistake-proof-your-processes","status":"publish","type":"post","link":"https:\/\/staging.opexlearning.com\/resources\/poka-yoke-system-design-how-to-mistake-proof-your-processes\/9131\/","title":{"rendered":"Poka Yoke System Design: How To Mistake Proof Your Processes"},"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>There are many <a title=\"example of coffee cup and of poka yoke\" href=\"https:\/\/staging.opexlearning.com\/resources\/a-coffee-cup-taught-me-about-poka-yoke-human-errors\/12986\/\">examples of Poka Yoke<\/a>. What is important and not discussed much is the foundation of Poka Yoke, which I call Poka Yoke System Design.<\/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><a title=\"poka yoke, mistake proof, error proof\" href=\"https:\/\/staging.opexlearning.com\/resources\/about-peter-abilla\/what-is-poka-yoke\/\">Poka-Yoke<\/a>, or Error-Proofing or <a title=\"poka yoke in a hospital\" href=\"https:\/\/staging.opexlearning.com\/resources\/everyday-poka-yoke-preventing-theft\/1993\/\">Mistake-Proofing<\/a>, is an essential aspect of process improvement. In fact, Poka-Yoke is the method by which we can actually get closer to a goal of zero defects without an exponential increase in the cost to detect and eliminate defects. In this article, I&#8217;ll discuss two types of situations that would benefit from the approach of Poka-Yoke and provide general guidelines on how to develop robust process and systems with the help of mistake proofing.<\/p>\n<p>In general, the approach of Poka-Yoke should follow the following guidelines:<\/p>\n<ol>\n<li>Inexpensive<\/li>\n<li>Based on common sense and obvious to the person involved in the process<\/li>\n<li>It MUST eliminate Occurrence and Detection of the problem at the root cause<\/li>\n<\/ol>\n<h2>Occurrence Poka-Yoke<\/h2>\n<p>Occurrence is the situation as it happens, but sometimes after the fact. An example would be a buzzer or warning light. For example, a fire alarm is a type of Occurrence Poka-Yoke. In general Occurrence situation that merit Poka-Yoke can happen:<\/p>\n<ul>\n<li>There is a chance that the required action is not performed<\/li>\n<li>There is a chance that the required action is performed incorrectly<\/li>\n<li>There is a chance that information required to perform an action is not understood or misinterpreted<\/li>\n<li>There is a chance that complexity of process could lead to defects<\/li>\n<\/ul>\n<p>For this situation, it&#8217;s important to follow these guidelines:<\/p>\n<ul>\n<li>At assembly, make sure that the wrong parts do not join together (think of Lego pieces that cannot join because they are not from the same Lego set).<\/li>\n<li>Use of 100% prevention devices such as contoured locators or fitted templates<\/li>\n<\/ul>\n<h2>Detection Poka-Yoke<\/h2>\n<p>In Detection, these situation should alert the operator at the point of mistake. For example, when one makes a mistake, an effective Poka-Yoke system will alert the operator that a mistake was made, where it was made, and even how the mistake was made.<\/p>\n<p>Here are some techniques for detection oriented Poka-Yoke:<\/p>\n<ul>\n<li>Use color coded parts of graphics or images<\/li>\n<li>Before the fact, or before the defective part\u00a0proceeds\u00a0to the next step in the process, a Poka-Yoke system should alert the operator that 100% quality does not exist.<\/li>\n<li>It should be autonomous, or require almost zero intervention, but be an automatic response to a defect; almost reflexive.<\/li>\n<\/ul>\n<div>These are just some general guidelines on the situations that merit a Poka-Yoke approach (almost all situations can benefit from Poka-Yoke thinking) and some general guidelines on how to develop the Poka-Yoke system itself.<\/div>\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>There are many examples of Poka Yoke. What is important and not discussed much is the foundation of Poka Yoke, which I call Poka Yoke System Design. Poka-Yoke, or Error-Proofing or Mistake-Proofing, is an essential aspect of process improvement. In fact, Poka-Yoke is the method by which we can actually get closer to a goal [&hellip;]<\/p>\n","protected":false},"author":12327,"featured_media":9132,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","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":""},"categories":[135],"tags":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v23.0 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Poka Yoke System Design Example<\/title>\n<meta name=\"description\" content=\"How to design a poka yoke system that will enable perfect systems and processes\" \/>\n<meta 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