{"id":13189,"date":"2025-06-16T15:40:48","date_gmt":"2025-06-16T14:40:48","guid":{"rendered":"https:\/\/selfbits.de\/uncategorized\/poka-yoke\/"},"modified":"2025-06-26T12:43:10","modified_gmt":"2025-06-26T11:43:10","slug":"poka-yoke","status":"publish","type":"post","link":"https:\/\/selfbits.de\/en\/learn\/poka-yoke\/","title":{"rendered":"Poka Yoke"},"content":{"rendered":"\t\t
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Startseite<\/a><\/span><\/span><\/p>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Poka Yoke<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\t\t\t\t\tAvoid \u201cunfortunate mistakes\u201d by using Poka Yoke to uncover errors and reduce opportunities for error.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Image: Sample illustration<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Introduction<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Description:<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The Japanese term Poka Yoke (meaning \u201cavoiding unfortunate mistakes\u201d) can actually be defined simply as \u201cavoiding mistakes\u201d. The fundamental goal is a zero-error state. At the same time, however, it is recognized that no system and no human being is able to completely avoid unintentional errors. They are part of every production and process. Poka Yoke therefore attempts to reduce or completely avoid errors with mostly simple but effective systems and to reduce the impact of errors in the production process on the end product. <\/p>

Shigeo Shingo is considered the inventor of the principle and the linguistic origin is derived from Go<\/a> and Shogi<\/a> (a Japanese variant of chess): In these, poka denotes a wrong move. In a broader sense, it means \u201cstupid mistake, blunder\u201d. Yoke comes from the verb yokeru, which means \u201cto avoid\u201d. <\/p>

As Poka Yoke was developed as part of the Toyota Production System<\/a>, it has its origins on the store floor. However, the principles also apply in the office, warehouse and service sector, as the examples below clearly show. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Advantages<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Processes in which fewer errors occur increase quality, but also have a significant impact on productivity. As the quality factor increases, the OEE<\/a> naturally also increases. Throughput times can often be reduced with less rework and simpler processes. Of course, there are also cost factors. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Application and basic rules<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The application of Poka Yoke is very simple: trace errors back to their sources and check how you can prevent the error from ever occurring again. <\/p>

The six basic rules help with the application and can be guidelines for a suitable solution<\/p>

  • Try not to spend money<\/li>
  • Simpler is better<\/li>
  • Do not make the use of Poka Yoke optional<\/li>
  • Do not confuse measuring instruments with errors<\/li>
  • Reduce decisions<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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    Procedure<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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    1. First identify the errors that occur in your production<\/li>
    2. Use the Pareto principle to decide which you should work on first<\/li>
    3. Find out the process step in which the observed error occurs<\/li>
    4. If your processes are not standardized, this should be the first step. Because designing a Poka Yoke for a non-repetitive process is a waste of time. <\/li>
    5. Think about what needs to be done to ensure that this error never occurs. This could be a change to the component, a change to the device or machine or other simple support for the workers at the workplace. <\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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      Examples from production<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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      Poka Yoke in Part Design<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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      Chamfer on a corner of a component to enable only one correct placement or connection (e.g. also SIM cards)<\/p>

      Staggered, asymmetrical placement of drill holes to create only one mounting option<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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      Poka Yoke in the design of devices and machines<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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      Position sensors only allow a pressing process to start when the component is inserted correctly<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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      Poka Yoke in process design<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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      Query of eye color in forms for customer service employees to ensure eye contact with the customer<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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      Examples from Everyday Life<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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      • Car key, USB type C and Lightning cable: They can be used on both sides and therefore cannot be used incorrectly.<\/li>
      • USB type A cables: they can only be plugged in in one orientation, often to the frustration of users <\/li>
      • Overflow drains in washbasins and bathtubs: They prevent the bathroom from flooding<\/li>
      • Cash machines: They first return the card and then dispense the cash withdrawn. This means that the card is less likely to be forgotten. <\/li>
      • Dispensing nozzles: They release their locking mechanism as soon as the tank is full, thus preventing overfilling and fuel leakage<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

        Poka Yoke, which means \u201cavoid unfortunate mistakes\u201d in Japanese, is a process design principle aimed at avoiding errors.<\/p>\n","protected":false},"author":16,"featured_media":12771,"comment_status":"closed","ping_status":"open","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"content-type":"","_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[32,30],"tags":[],"class_list":["post-13189","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-lean-management","category-learn"],"yoast_head":"\nPoka Yoke - Selfbits GmbH<\/title>\n<meta name=\"description\" content=\"Poka Yoke, which means \u201cavoid unfortunate mistakes\u201d in Japanese, is a process design principle aimed at avoiding errors.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/selfbits.de\/en\/learn\/poka-yoke\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Poka Yoke - 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