How can you prevent errors and defects using Poka-Yoke in Lean Six Sigma?

1 What is Poka-Yoke?

Poka-Yoke is based on the idea that human errors are inevitable and can occur at any stage of a process or product life cycle. However, these errors can be prevented or detected by designing the process or product in such a way that it either makes it impossible to make a mistake or alerts the user when a mistake is made. Poka-Yoke can be applied to any type of process or product, whether it is manufacturing, service, or administrative. Poka-Yoke can take various forms, such as physical devices, visual cues, checklists, standard operating procedures, or software features.

3 How to apply Poka-Yoke in Lean Six Sigma?

To apply Poka-Yoke in Lean Six Sigma, you should first identify the potential or actual errors, defects, or failures that occur in the process or product. You can use tools such as brainstorming, fishbone diagram, Pareto chart, or FMEA to analyze the sources and impacts of these problems. Then, determine the type and level of Poka-Yoke that is appropriate for the problem. There are two types – prevention and detection – as well as three levels – contact, fixed-value, and motion-step. Once you have decided on the Poka-Yoke solution, design and implement it. You can use existing or new devices, methods, or features and should test and validate its effectiveness and usability. Finally, you should monitor and evaluate the Poka-Yoke solution by collecting data on its performance and outcomes and soliciting feedback from users and customers.

4 Examples of Poka-Yoke in Lean Six Sigma

Poka-Yoke can be found in many processes and products across different industries and sectors. For instance, a car key that can only be inserted in one way prevents incorrect insertion or damage to the ignition. A microwave oven stops working when the door is opened, avoiding radiation exposure or fire hazard. Similarly, a checklist guides the pilot through pre-flight procedures to avoid missing any critical steps or actions. Furthermore, a barcode scanner verifies the accuracy and completeness of an order before shipping it to the customer. Lastly, a software feature prompts users to save the file or confirm an action before closing the application or performing a deletion.

5 Tips for using Poka-Yoke in Lean Six Sigma

When using Poka-Yoke in Lean Six Sigma, it is important to involve users, customers, and stakeholders in the design and implementation of the solution. The Poka-Yoke should be kept simple, clear, and intuitive. Additionally, one should consider the cost and benefit of the solution and review and improve it regularly. It is also essential that the Poka-Yoke does not add complexity or confusion to the process or product. It should be easy to maintain, update, and modify as needed. Moreover, it should not be too expensive or resource-intensive to implement and operate. Ultimately, the cost of quality, efficiency, and customer satisfaction resulting from having a Poka-Yoke solution should outweigh that of not having one.