Poka Yoke

What is Poka Yoke?

Poka Yoke is a Japanese term from the Lean methodology and literally means error prevention. It is a technique that designs production or work processes in such a way that it becomes almost impossible to make mistakes. By cleverly designing the process, the correct action is automatically encouraged or even enforced.

The method was developed by Shigeo Shingo, one of the founders of the Toyota Production System. It has since become known worldwide as a practical way to prevent errors at the source rather than detecting them after the fact.

Benefits in practice

Typical Poka Yoke solutions are simple, smart and immediately applicable. They prevent human error and increase process reliability.

Some benefits at a glance:

• Errors are prevented at the source rather than corrected
• Less need for extensive quality controls
• Operators are relieved of repetitive checks
• Problems are immediately visible and addressed
• Constant quality control is built into the process
• Customers will not receive defective or incomplete products