Poka-Yoke

Question 1

What is Poka-Yoke?

Answer 1

Guidelines for producing designs or products and processes which are inherently reliable and resistant to operator mistakes

Question 2

What are the two primary principles of Poka-Yoke?

Answer 2

1) Design a process or product so that a defect cannot be made
2) Design a process/product so that if a defect is created, it is immediately obvious

Question 3

What does the process of Poka-Yoke involve? (3)

Answer 3

1) Selfchecks - best person to check is the operator
2) Successive check - in-assembly lines, checked by the next operator
3) Source inspections - inspect the source of mistake straight away

Question 4

What are the three general categories of approach to Poke-Yoke?

Answer 4

1) Contact type - use of shape to detect the contact or non-contact
2) Constant number type - detects error if a fixed number of parts have not been made

3) Performance sequence type - detects errors if the fixed steps in a sequence have not been performed

Question 5

In Poke-Yoke, what are attention actions and shut-out actions?

Answer 5

Attention actions - bring attention to incorrect action but does not prevent it happening again

Shut-out action - prevent incorrect action taking place again