Looking for perfection? Try borrowing an approach from the Japanese that allows you to weed out errors in your process before they can occur.
Companies all around the world would love to be error-proof in order to prevent reproduction costs. Usually, startup companies lacking experience face the highest number of errors and mistakes.
Poka-yoke, a Japanese term for mistake- or error-proof, was coined as a technique by Shigeo Shingo, a Japanese industrial engineer who wanted to eliminate quality control and prevent defects once and for all.
Why is this technique important?
Poka-yoke helps people and processes work correctly the first time. This technique can drive defects out of products and processes while substantially improving quality and reliability. Ideas and methods, intentionally placed within the planned evolution of products during the design process, gain the potential to eliminate both human and mechanical errors.
When should it be used?
Poka-yoke can be used wherever something could potentially go wrong, or an error could be made. It is a tool that can be applied to any type of process in the manufacturing or service industries.
“Poka-yoke can be used wherever something could potentially go wrong, or an error could be made.
Errors can come in many forms:
- Processing errors: The process operation has been missed, or not performed according to standard operating procedure.
- Set-up errors: The wrong tools have been used, or the machine adjustments have been set incorrectly.
- Missing parts: Not all of the necessary parts have been included in the assembly, welding, or other processes.
- Improper parts/items: The wrong parts have been used in the process.
- Operations errors: An operation has been carried out incorrectly; an inaccurate version of the specifications has been employed.
- Measurement errors: Errors have occurred in machine adjustment, test measurements, or the dimensions of a part coming from a supplier.
How is it used?
- Here’s a step-by-step process for applying Poka-yoke:
- Identify the operation or process.
- Analyze how the process could fail.
- Decide upon the Poka-yoke approach, such as using a shut-out type (prevention of errors) or an attention type (highlighting the fact that an error has been made).
- Determine the approach you are dealing with:
- Contact: use of shape, size, or other physical attributes for detection
- Constant number: error triggered if a certain number of actions are not made
- Sequence method: use of a checklist to ensure that complete all process steps is appropriate
- Trail the method and see if it works.
- Train the operator, review performance, and measure success.
Poka-Yoke is the perfect technique for any type of industry that aims to achieve perfection and reduce the cost of defects.
