Utilization of Poka-Yoke Method for Preventing Human Error
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Utilization of Poka-Yoke Method for Preventing Human Error
By Reinaldo Ragil Rompas
Poka-Yoke is a typical approach applied by Toyota’s Production System (TPS) in order to avoid trivial mistakes or human error. Toyota created TPS, a standard management framework for manufacturing and logistics. The term Poka Yoke originates in Japanese and refers to preventing basic mistakes that are frequently made as a result of human negligence. Poka translates to Poka Poka Misu, meaning a reckless mistake. While Yoke is Yokeru, which means to avoid.
Shigeo Shingo first introduced the Poka-Yoke idea in the 1960s, and it was later implemented into Toyota’s Production System. Shigeo Shingo was an engineer at Matsushita Manufacturing, which eventually became a member of the Toyota Production System. This strategy was formerly known as baka-yoke, which means “fool-proofing” or “idiot-proofing”, before being renamed Poka Yoke. The change was made because the prior name had an improper name or sounded too harsh, so it was modified again and declared to be “poka-yoke”. Shigeo additionally divided poka yoke into three types, which are as follows:
1. Contact Method
This method is ideal when it involves something tangible on the product that has to be checked to guarantee there are no flaws, or while the physical structure of an operation can prevent errors. To utilize a contact poka-yoke to look for mistakes, include a phase in your process where you need to evaluate a physical element of the item that might lead to a critical error. For avoiding errors, consider using a physical instrument, such as a jig, to make a procedure simpler to carry out without error.
2. Fixed-Value Method
The fixed-value method implies notifying a worker when a certain number of actions are not completed. This would be useful in a circumstance if the number of activities is precisely specified, and each is crucial to the process’s overall outcome.
3. Motion-Step Method
The motion-step method necessitates using a procedure checklist and verifying that every step (and just the relevant steps) is followed. This can be done best by guiding the employee through the process with electronic instructions or a comparable system, which will prevent errors and require rework.
The design of poka yoke includes a notion known as the “three basic functions of the poka yoke,” which consists of three concepts: control, shutdown, and warning. Control is the role of observing or supervising a procedure in order to avoid errors or harm from occurring or progressing to the next step. While shutdown is a state in which work is halted when a mistake or damage is recognized. Also, warning is a function that alerts you when there is an unusual condition, error, or harm.
Poka-yoke provides numerous benefits to both businesses and employees. We will go over four major benefits further below.
- Reduced Waste
Waste reduction is unavoidable when well-designed systems are in place to eliminate mistakes and rapidly detect any that do occur. Poka-yoke achieves this goal by incorporating quality throughout the processes, lowering the requirement for rework by minimizing defects.
- Reduced Training Time
Since poka-yoke emphasizes avoiding faults in an operation, it is difficult to get the work incorrect. This means that training workers will take shorter because the procedure will include instructions or stages that eliminate the need for memorization or specialized training.
- Improved Safety
Poka-yoke can handle the majority, if not all, of occupational dangers. For example, making it physically difficult to begin operating an equipment till the worker is in a safe zone incorporates safety throughout the work process. This style of thought can be utilized in each facility in a variety of ways, with the goal being to make it hard (preferably impossible) to become hurt accidently.
- Higher Productivity
Company facilities will witness increased production as personnel spend less time wondering what step to take next, reworking flaws, making mistakes, and training. Effective poka-yoke implementation influences the entire line by eliminating errors, ambiguity, and additional waste, resulting in a better production process.
Applying the poka-yoke method will result in low error rates in your firm, allowing the level of production as well as corporate activities to earn large profits.
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