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What are the most common misconceptions about Poka-yoke and mistake-proofing in Lean Manufacturing?

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Poka-yoke and mistake-proofing are two terms that are often used interchangeably in Lean Manufacturing, but they actually have different meanings and applications. Poka-yoke is a Japanese term that means "mistake-proofing" or "error prevention", while mistake-proofing is a broader concept that includes any method or device that prevents or detects defects in a process. In this article, you will learn about some of the most common misconceptions about Poka-yoke and mistake-proofing in Lean Manufacturing, and how to avoid them.

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1 Misconception 1: Poka-yoke is only for manufacturing

One of the most common misconceptions about Poka-yoke is that it is only relevant for manufacturing processes, and not for service or office environments. However, Poka-yoke can be applied to any process that involves human interaction, such as filling out forms, entering data, scheduling appointments, or delivering services. Poka-yoke can help reduce errors, waste, and rework in any setting, as long as the process is well-defined and standardized. For example, a Poka-yoke device could be a checklist, a barcode scanner, a color-coded system, or a software alert.

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Shuresh K

Mechanical Engineer With Three Decades of Engineering Industry Experience and Five years of E-learning Industry Experience.
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A conventional checklist cannot be considered as a poka-yoke as it is 100% dependent on humans. Any activity that involves humans are prone to errors due to fatigue, complacency, wilfull bypassing of procedures etc. However, if filling of a checklist is automated, with interlinked controls on the various checkpoints, then it can be considered as a poka-yoke.

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2 Misconception 2: Poka-yoke is expensive and complicated

Another misconception about Poka-yoke is that it requires expensive and complicated technology or equipment to implement. However, Poka-yoke can be simple and low-cost, as long as it is effective and reliable. Poka-yoke devices can be made from readily available materials, such as magnets, pins, springs, or labels. The key is to design the Poka-yoke device based on the root cause of the error, the frequency of the error, and the impact of the error. For example, a Poka-yoke device could be a simple jig that ensures the correct alignment of a part, or a sensor that detects the presence or absence of a component.

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Caio Benitz

Gerente de Projetos & QSMS | ESG
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Um equívoco comum sobre o Poka-yoke é considerá-lo apenas como um dispositivo físico para evitar erros, quando na verdade pode ser um sistema, procedimento ou até mesmo um alerta visual. Outro equívoco é acreditar que à prova de erros significa eliminar completamente os erros, quando na realidade se trata de projetar sistemas que minimizem ou detectem falhas antes que causem problemas maiores. Ambos os conceitos, Poka-yoke e à prova de erros, s?o mais sobre preven??o e detec??o precoce do que sobre elimina??o total de erros.

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3 Misconception 3: Poka-yoke is a one-time solution

Another misconception about Poka-yoke is that it is a one-time solution that does not require any maintenance or improvement. However, Poka-yoke is not a static or permanent fix, but a dynamic and continuous process that needs to be monitored and evaluated regularly. Poka-yoke devices can become obsolete, ineffective, or bypassed over time, due to changes in the process, the environment, or the customer requirements. Therefore, Poka-yoke devices need to be checked and updated periodically, based on feedback, data, and customer satisfaction. For example, a Poka-yoke device could be modified to accommodate a new product feature, or a new Poka-yoke device could be added to address a new source of error.

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Shuresh K

Mechanical Engineer With Three Decades of Engineering Industry Experience and Five years of E-learning Industry Experience.
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One vital activity is to define a frequency to verify the functioning of the poka-yokes by the concerned users in the process line, preferably at the start of production. If this verification system is not in place, the risk of defective pieces escaping to the subsequent stages increases, in case the poka-yoke fails to deliver the planned controls.

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Shuresh K

Mechanical Engineer With Three Decades of Engineering Industry Experience and Five years of E-learning Industry Experience.
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One vital activity is to define a frequency to verify the functioning of the poka-yokes by the concerned users in the process line, preferably at the start of production. If this verification system is not in place, the risk of defective pieces escaping to the subsequent stages increases, in case the poka-yoke fails to deliver the planned controls.

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4 Misconception 4: Poka-yoke is only for preventing defects

Another misconception about Poka-yoke is that it is only for preventing defects from occurring in the first place, and not for detecting or correcting defects that have already occurred. However, Poka-yoke can be used for both prevention and detection, depending on the type and stage of the process. Prevention Poka-yoke devices are designed to eliminate the possibility of errors, by making it impossible or difficult to perform the wrong action. Detection Poka-yoke devices are designed to identify and signal errors, by making them visible or audible to the operator or the customer. For example, a prevention Poka-yoke device could be a lock that prevents the wrong key from being inserted, or a detection Poka-yoke device could be a light that indicates the status of a machine.

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5 Misconception 5: Poka-yoke is a substitute for training and empowerment

Another misconception about Poka-yoke is that it is a substitute for training and empowerment of the workers, and that it reduces their creativity and responsibility. However, Poka-yoke is not a replacement for human skills and judgment, but a support and a tool that enhances their performance and productivity. Poka-yoke devices are not meant to control or restrict the workers, but to assist and guide them in achieving quality and customer satisfaction. Poka-yoke devices are also not meant to stifle or discourage innovation, but to stimulate and encourage improvement and problem-solving. For example, a Poka-yoke device could be a reminder or a prompt that helps the worker to follow the best practice, or a feedback or a suggestion that helps the worker to improve the process.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the most common misconceptions about Poka-yoke and mistake-proofing in Lean Manufacturing?

1

2

3

4

5

6

1 Misconception 1: Poka-yoke is only for manufacturing

2 Misconception 2: Poka-yoke is expensive and complicated

3 Misconception 3: Poka-yoke is a one-time solution

4 Misconception 4: Poka-yoke is only for preventing defects

5 Misconception 5: Poka-yoke is a substitute for training and empowerment

6 Here’s what else to consider

Lean Manufacturing

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What are the most common misconceptions about Poka-yoke and mistake-proofing in Lean Manufacturing?

1

2

3

4

5

6

1 Misconception 1: Poka-yoke is only for manufacturing

2 Misconception 2: Poka-yoke is expensive and complicated

3 Misconception 3: Poka-yoke is a one-time solution

4 Misconception 4: Poka-yoke is only for preventing defects

5 Misconception 5: Poka-yoke is a substitute for training and empowerment

6 Here’s what else to consider

Lean Manufacturing

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