Poka-Yoke, Mistake Proofing or Fail-Safe, Point of origin inspections (Proactive approach), Informative Inspection (Reactive Approach)

Poka-Yoke

A method that uses sensor or other devices for catching errors that may pass by operators or assemblers, also known as “Mistake Proofing” or “Fail-Safe”

• Identifying the defect immediately (Point of Origin Inspection)
• Quick Feedback for Corrective Action

How effective the system is depends on where it is used

• Point of Origin Inspections (Proactive Approach)
• Informative Inspection (Reactive Approach)

Point of origin inspections (Proactive approach)

A fully implemented system requires Poka-yoke usage at or before the inspection points during the process.

• Poka-yoke will catch the errors before a defective part is manufactured 100% of the time

Informative inspection (Reactive approach)

• Check occurs immediately after the process
• Can be an operator check at the process or successive check at the next process
• Not 100% effective, will not eliminate all defects
• Effective in preventing defects from being passed to next process

Two Poka-Yoke System approaches are utilized in manufacturing

• Control Approach (Shuts down the process, Keeps the “suspect” part in place)
• Warning Approach (Signals the operator to stop the process & correct the problem)