Poka Yoke - An Overview

When hearing the term poka yoke, what comes to mind? You may think that it’s the weird dance that your uncle does whenever he’s drunk at parties, but it’s actually pretty far from it. Poka yoke is a Japanese term that means mistake-proofing. It’s a term that’s commonly associated with lean marketing principles.

The goal of poka yoke is to avoid making product defects by preventing and correcting errors as they happen. The term was coined by Shigeo Shingo in the 1960s for the Toyota production system. It was first called as “baka-yoke”, meaning fool-proofing. The concept makes sure that quality products are made in the right environment by preventing any errors or finding them and fixing them as early as possible.

Nobody likes to invest and buy from an error-laden company. One of the benefits of poka yoke is that it helps business processes run more efficiently, doing the job right the first time. It teaches you how to prevent errors, resulting in a more reliable business, better quality products, and higher customer satisfaction.

A poka yoke game shows that this practice can be applied in any business process where things are vulnerable to errors. It can be implemented to prevent different kinds of errors. One such error is an operational error, wherein a faulty operation is carried out. Another example would be machine setup or missing parts. Poka yoke makes sure that all the parts are setup and installed correctly.

By playing a poka yoke game or simulation, employees and managers alike will learn how to make an environment completely fail-proof. First, analyze the process and ask yourself how, why, and when can this process go wrong. Next is to determine which approach of poka yoke to use; will you prevent or point out the error and fix it accordingly? You can either test the product, have a checklist to see if all the fundamental steps were followed, or become alerted if a certain number of steps weren’t done.

Test the techniques to see if it works to your advantage. A poka yoke game shows you that the practice can not only catch mistakes, but effectively prevent them. Compared to other techniques, it’s the fastest way to reduce errors. You’ll not only reduce defects, but you’ll produce goods of the utmost quality. When a customer gets quality and defect-free products, you get yourself a satisfied and loyal customer.