Poka Yoke

The Japanese term Poka Yoke (Japaneseポカヨケ, dt " avoid unfortunate mistakes" ) refers to an existing multi-element principle, which includes technical arrangements or facilities for immediate error detection and prevention. As the inventor of the principle applies Shigeo Shingo.

Poka Yoke is similar as fehlervermeidendes principle the biochemical key - lock principle that acts fehlerminimierend about in the duplication of genetic information.

Name

Poka denotes a wrong train in the Go or Shogi and in a broader sense " stupid mistakes, blunders " in general. yoke comes from the verb yokeru from " avoid " to German.

Method

Basis for Poka Yoke is the realization that no man and no system is able to completely avoid inadvertent error. With Poka Yoke is usually taken care of by simple and effective systems that wrongdoing not result in the production process errors on the final product. This Poka Yoke aims at the use of most technical aids. These solutions are usually inexpensive and immediately inserted.

In order to exclude a further occurrence of errors once discovered, Poka Yoke in connection with an inspection method, source inspection is employed. Poka -Yoke in combination with the source Inspection found the methodology of the Poka -Yoke System.

Examples

  • Acetylene cylinders have a unique connection bracket to prevent the dangerous confusion with other gases.
  • CEE plugs have depending on the voltage and frequency of different colors and contact arrangements, to avoid confusion.
  • Each component must be enabled to verbauende via barcode or RFID scan before installation.
  • Depending on the valid routing only the matching component compartments are opened.
  • Through a pick- by-light device Kommissionierungsfehlern is prevented.
  • TAE plug can not be wrong plug around.
  • ATMs in Germany give the money out first when the card was removed. This prevents that you forget the card.
  • SIM cards can be inserted only in the correct orientation in the SIM card slot because of their shape.
  • USB plug can only be inserted in a particular direction.
  • Position sensors at a press let the pressing process start only when the component is inserted correctly
  • Query the eye color in forms for the customer service staff to ensure eye contact with the customer
  • The query located above the rollers Shopping Cart number at the supermarket checkout to force cashiers to look at the bottom shelf of the cart

History

The starting point for the development of the poka-yoke system with sources of error inspection for Shigeo Shingo was in statistical quality control ( SQC ). However, he stated that " errors are generated in the working phase, and trials may cause nothing more than to find the error. "

The Toyota Production System (TPS), in which a substantial part of Poka Yoke is regarded as a key for the market success of the Japanese automobile company.

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