SAVITRIBAI PHULE, PUNE UNIVERSITY

A Seminar Report
On

QUALITY IMPROVING TOOL

POKA-YOKE
By

TANDLE UMAKANT VASANTRAO

Guided by

Prof. T.J.RANE

Department of Mechanical Engineering

P K Technical Campus
Chakan Pune-410501
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CERTIFICATE
This is to certify that Mr. TANDLE UMAKANT VASANTRAO has successfully
completed the Seminar work entitled QUALITY IMPROVING TOOL POKA
YOKE under my supervision, in the partial fulfillment of third year Mechanical
Engineering, by Savitribai Phule Pune University.

Date:
Place: Chakan
__________________
Guide_____________ Head Department_____________
Name: _________________ Name:______________________

Principal______________
Seal Name_________________

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ACKNOWLEDGEMENT
We are highly grateful to our Director Dr. Sanjay Singh and Principal institute for giving all
the facilities in completing project.
The Project is highly technical could not have been completed without sincere help and
facilities provided by H.O.D of Mechanical Engineering. This is to acknowledgement our
indebtedness to our guide Prof. T. J. RANE for his constant guidance and helpful suggestions
for preparing dissertation.
Our deep gratitude towards for all inspirations personal involvement, constructive, criticism
which have provided beyond more technical guidance during causes of this dissertation. He also
took grade print in going through the manuscript carefully and correctly which have greatly
improve the quality of text. He shares enthusiasm taught us patience and these words of advice
as morale booster.

By
TANDLE UMAKANT VASANTRAO

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Contents

1. ABSTRACT:...........................................................................................................................5
2. INTRODUCTION:.................................................................................................................6
3. LITRATURE SURVEY:.......................................................................................................7
4. WHAT IS POKA-YOKE:......................................................................................................8
5. NEED OF MISTEK PROFLE:...........................................................................................09
6. TYPES OF POKA-YOKE:..................................................................................................10
7. STEPS OF IMPLEMENT POKA-YOKE.........................................................................11
8. PRINCIPLES ……………………………………………………………………………...13
9. CONCLUSION…………………………………………………………………………..17
10. REFERENCES:………………………………………………………………………..18

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1. ABSTRACT

Purpose: A new approach for the implementation of quality philosophy Zero Quality Defects
with usage of the Poka-Yoke method in the polish organization has been presented.
Design/methodology/approach: The possibility of usage of mistake proofing device is
connected with monitoring and improvement of operations in the process.
Findings: At the present time the organizations should implement quality tools, techniques,
methods which support the prevention strategy and should pay attention to improving each
element and operations in the process.
Research limitations/implications: Generally activity aim at prevent defects has been
described. The Poka-Yoke method of preventing errors by putting limits on how operation can
be performed in order to force the correct completion of the operation has been presented.
Practical implications: The possibility of implementing of the Poka-Yoke method as a factor of
improving operation in the process in the motorizations companies has been shown.

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1. INTRODUCTION

In today’s competitive world any organisation has to manufacture high quality, defect free
products at optimum cost. The new culture of total quality management, total productive
management in the manufacturing as well as service sector gave birth to new ways to improve
quality of products. By using various tools of TQM like KAIZEN, 6 sigma , JIT, JIDCO , POKA
YOKE, FMS etc. organisation is intended to develop quality culture. The paper is intended to
focus basic concept of poka yoke, types of poka yoke system, ways to achieve simple poka yoke
mechanism. It also covers practical study work done by various researcher . In the recent years
intensifying competition in the international economy caused a major change in approach to
quality management. The quality action should therefore include its reach the whole product life
cycle, starting from customer identification requirements and expectations, by the customer’s
service. The organizations by focusing on quality process approach should improve the existing
quality management system, the defined processes and also their products by implementing the
available philosophy (Kaizen, TQM, Zero quality defects), rules quality tools and methods of
quality management “Process approach” to management of organization is a field developing
dynamically. This concept is very universal , it works for all companies, because it integrates in
transparent way all key mechanisms which result from requirements for quality management
system and quality processes

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3.LITRATURE SURVEY

Poka-yoke is a Japanese term that means "mistake-proofing". A poka-yoke is any mechanism in

a lean manufacturing process that helps an equipment operator avoid (yoke) mistakes (poka). Its
purpose is to eliminate product defects by preventing, correcting, or drawing
attention to human errors as they occur. The concept was formalised, and the term adopted, by
Shigeo Shingo as part of the Toyota Production System. It was originally described
as poka-yoke, but as this means "fool-proofing" In today’s competitive world any organization
has to manufacture high quality, defect free products at optimum cost. The new culture of total
quality management, total productive management in the manufacturing as well as service sector
gave birth to new ways to improve quality of products. By using various tools of TQM like
KAIZEN, 6 sigma, JIT, JIDCO, POKA YOKE, FMS etc. organization is intended to develop
quality culture.

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4. What Is Poka Yoke?

Poka-yoke is a Japanese improvement strategy for mistake-proofing to prevent defects (or

nonconformities) from arising during production processes. Poka-yoke is a preventive action that
focuses on identifying and eliminating the special causes of variation in production processes,
which inevitably lead to product nonconformities or defects. This concept was initially called
Idiot Proofing but it was understood that this name may heart workers so term Mistake Proofing
was coined by Shigeo Shingo. Poka-yoke gives a strategy and policy for preventing defects at the
source. These solutions are not only cost-effective but also easy to understand and apply. It is
one of the important tools to add to any organization’s Continuous improvement. In short poka-
yoke is a continual improvement strategy that offers a way to move the QMS (quality
management system) towards a higher level of performance .The poka-yoke concept was
generated in the mid-1960s by Shigeo Shingo who is Japanese industrial engineer. Shingo was
working for Toyota and other Japanese companies, where he developed entire production
systems focused on achieving zero defects in production and gave birth to this revolutionary
work. The basic concept behind poka-yoke is that it is not acceptable and allowed to produce
even a small amount of nonconforming product. To stay in market and to become a world-class
competitor, an organization must go with new philosophy and technology along with side by side
practice of producing zero defects. Poka-yoke methods are the very easy and simple concepts for
achieving this goal and are a key component of the continual improvement strategy in many
leading Japanese companies on this moment. Poka-yoke is one of the presentations of “good
kaizen”, or superior continual improvement because of its preventive nature. A poka-yoke device
or solution is any mechanism or idea that either avoids the mistake from being made or makes
the mistake easily detected at a glance. The ability to find mistakes at a glance is important
because, as Shingo states, "The causes of defects lie in worker errors, and defects are the results
of neglecting those errors. It follows that mistakes will not turn into defects if worker errors are
discovered and eliminated beforehand" He also adds to this that "Defects arise because errors are
made; the two have a cause-and-effect relationship. ... Yet errors will not turn into defects if
feedback and action take place at the error stage

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5.Need Of Mistake Proofing

When any organization decides to implement the lean manufacturing then one of the objective is
to reduce scrap because no one is interested to compensate extra inventory on account of scrap.
As per philosophy of lean manufacturing it focuses on speed of production and productivity also.
In order to follow this concept of speed we should prevail against defects and rework. To
increase profit percentage the cost pressures always become headache for top management so
they never accept continued mistakes like scrap, rework, lateness etc out of tolerance instead
they are aiming to achieve value of zero in this segment. When customers of any company buys
product they rightfully expect defect free products and conventional 100% inspection or
statistical process control don’t insure 100% defect-free products. Hence we are going to root
cause of any problem and avoiding it which gives us defect free product. The above discussion
concludes that to get defect free products one should go with the concept of Poka Yoke.

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6. Types Of Poka Yoke

The Poka-Yoke is a technique for to keep away human error at work. A defect or imperfection
exists in either of two states; the defect either has already occurred in that case calling for
defect detection, or is about to occur in that case calling for defect prediction. The technique
starts by analyzing the process for potential problems, identifying parts by the characteristics of
dimension, shape, and weight, detecting process deviation from nominal procedures and
norms. Depending on the basic functionality Poka-yoke has three types:[2]
1] Shutdown Poka yoke
2] Control Poka yoke
3] Warning Poka yoke

6.1 Shutdown (Prevention) Method In shut down i.e. prevention method Poka-yoke devices
checks critical process parameters and shut down the process when a situation moves out of the
tolerance zone, it is indication of a defective product has either been produced or is about to be
produced. It is well known note that prevention is always better than cure. By implementing
shutdown method we can assure about 100% defect free products. It has 0 % chances to produce
defective product, up to this level we can reliance on it. E.g. Use of fuse in electric circuit. When
there is short circuit then fuse is operated and cut down the supply of electricity resulting in
avoiding any further accidents
6.2 Control method In control method Poka-yoke devices are regulatory in working which are
installed on process equipment and/or Work pieces which make it impossible to produce defects
and/or to flow a nonconforming product to the next process. As like shut down method control
method gives 100% defect free products. The control make certainty that if there is any defect,
it’s not coming outside the production line and does not reach to the customer. E.g. To avoid
wrong job loading in reverse direction on machine we can provide work rest for the job which
will avoid wrong job loading.

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6.3 Warning (Alert) method This is the method which makes the operator conscious about
something is going wrong. The mechanism or simple idea is generated in such a way that Poka-
yoke devices indicate or shows to a worker that a defect has been produced. When operator gets
such warning then he must immediately interfere the process to correct the process responsible
for causing the defect. In case of irresponsible behavior of operator irrespective of getting
warning notice the next products will continue the same defect and produce nonconforming
products. In short again this method depends on human nature and behavior. It is concluded that
alert method gives 30% of the guarantee of good products. Actually this method tells about
existence of defect but does not assure and does not produce 100% quality. The common
warning methods are use of blinking light and use of beeping sound as alarm. e.g. Beeping sound
or flashing of light in ATM machine after removing ATM card from machine to warn operator
that he is safe and ensure that card is not in machine

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7.Steps to implement poka yoke

7.1 Identify problem In this stage the complaints coming from the customers (Both internal and
external customer) are collected. The principle of standard is determined by considering various
criteria’s like number of complaints from the customer, the quantity of defects detected by
quality control, materiality defects (their impact on the customer, costs, implemented process)
and then data is collected broadly. As per analysis results of the collected data company plans for
developing poka yoke system for the selected problem. In this way in first stage the problem is
selected ,
7.2 Observation at work stations In this step the actual on site study of the problem is carried
out. The causes behind the problem are sort out by using fishbone diagram (fishbone diagram is
cause and effect diagram given by Japans management guru Ishikawa).The causes may be
related to man, machine, material or method accordingly the complete sorting is carried out.
7.3 Brainstorming for Idea This is a technique to capture creativity and skills of employee’s
.In brainstorming session the problem under study is put forward to committee. Then all
members study problem and give various solutions to avoid that defect. As each person has one
uniqueness this step concludes with various alternative solutions for same problem.
7.4 Select best ideas After getting various alternative solutions it is time to select best one out
of all collected solutions. Criteria for selection may be cost, time required, changes in existing
system, opportunity to develop new solutions, simplicity in operation etc. By referring all
selection criteria’s committee concludes With one best solution.
7.5 Implementation plan and implementation This step is concerned with implementation
planning. It deals with material requirement, processing the material and finally manufactured
mechanism is implemented at actual working site.
7.6 Monitoring and sign off The manufactured products are checked for defects under study
also the performance of poka yoke system is also monitored and project is shut downed.

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Example:- Problem: - Job loading in reverse direction causing job rejection, damage to tool and
machine geometry

Aim: - To ensure correct loading of job

Ideas After Brain Storming:-When problem is taken on the table of brainstorming the
following options are obtained for above mentioned problem
1. Use of proximity sensor to detect reverse loading of job.
2. Use of photo sensor.
3.Instructions to operator.
4. Separate fixtures to keep the incoming job to enable operator to load the job correctly.
5. Painting the correct and wrong end of job with different colors.
6. Use of color sensors to differentiate between correct and wrong end of job.
7. To provide work rest for the job.
8.To provide mechanical stopper. Etc.

FIG 1

Now they will plan for implementing the selected solution and monitor for the result and switch
over to next problem.

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8. Principles Of Poka Yoke

Imperfections faults arise most as a result of human errors and mistakes. Even though the worker
is conscious of the mistake he makes, he repeats to do the same. Here is list of some most
common errors incurred by operators as below- [1, 5]
1) The errors due to the misunderstanding
2) Incorrect identification
3) Good intentions but improperly implemented
4) Processing omissions (a step was forgotten)
5) Processing errors (something was done incorrectly)
6) Error in setting up the work piece
7) Assembly omissions (a part was forgotten)
8) A wrong part / item was included
9) Wrong work piece
10) Operations errors (incomplete information, Lack of training ,procedures not followed)
11) Adjustment, measurement, dimensional errors
12) Equipment maintenance errors
13) Errors in preparation of tools, fixtures, blades etc. Etc.

All errors arising in the company are kept on record and then analzed. Most of them can be
prevented by using techniques Poka-Yoke.

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9. Methods Of Obtaining Poka Yoke

Poka yoke ideas are simple but creative in operation and generation. According to Shingo ,
"Defects will never be reduced if the workers involved do not modify operating methods when
defects occur." Following are some of the simple ideas (hints) to avoid mistakes: -
1) Using Shapes and Colors
2) Software Warnings and Reminders
3) Using Dialogue Boxes and Software Checks
4) Using Switches and Automatic Braking
5) Using Checklists
6) Visual Prevention Methods
7) Using Lights, Sounds, Signs and Barriers Etc.

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10.Challenges And Limitations Of Poka Yoke

As per up till discussion in the paper it seems that poka yoke is one of the best tool in total
quality management but we have to think about the obstacles and challenges against poka yoke.
Some of challenges are listed below-
1. Practical implementation of the mechanism or solution is not possible.
2. Process parameters don’t allow changing the existing system.
3. Sometimes the poka yoke is not cost effective.
4. Interdepartmental relations between production and quality dept are not good so each one
think that I don’t have to do anything with that issue.
5. Now also we are depending on statistical process control.
6. Expert advice is needed for new creative and challenging tasks .It may happen that experts are
not available with small scale industries and expert advice is not economical for their financial
health.

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11. Examples Of Poka Yoke

1. Spindle of CNC machine starts only after closing the safety door. If door is open then machine
will not run. It is shut down poka yoke to avoid accidents.
2. The guide pins are used in stamping dies for correct alignment of upper and lower portion. If
there is improper matching assembly of dies will not take place. It is shut down poka yoke.
3. If we want to close any file in operating software (e.g. Microsoft Word) it asks for save it or
cancel dialogue box. This is warning system against by mistake closing of file. It is warning poka
yoke.
4. To avoid parallax error in reading the measuring instrument small mirror is placed below the
moving pointer. By referring pointer and its mirror image we can take proper reading. It is
warning poka yoke.
5. The socket for USB on the computer is designed in such a way that we can’t connect pen drive
or any corresponding pin in opposite or wrong way. It is control poka yoke system.
6. Pressure relief valves are used in hydraulic circuit to prevent damage to system due to high
pressure. In case of high pressure the excess oil bleed off through check valve to the reservoir. It
is control poka yoke system.
7. Check list is used to confirm that all subcomponents in assembly are assembled. It is control
poka yoke system.

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12. Conclusion
To error is human nature so we can’t blame human being for each and every mistake. As like
err, Intelligence is also human nature so we can dominate preceding nature by next nature. Poka
yoke is just a face of that intelligence. We can avoid the mistakes at the source itself by using
above mentioned methodology. About mistake proofing we can say that it is a system for
organizing work that eliminates any chances of error by new user also. It also allow user to
function without mistake or prevent error that are about to occur. In order to implement quality
management system successfully each activity should aim towards excellence. Poka yoke is one
of the most important tool in TQM. Successful poka yoke results in increased productivity with
minimum waste (waste due to rework, scrap) because we are sure about the quality of product, as
mistakes are blocked at source itself. There may be some practical limitations in poka yoke but
we have to overcome all that for achieving the aim of “Zero Defects, Zero Waste and Zero
Delays”. In one sentence poka yoke is launching preventive actions for systematic movement on
the success ladder of QMS with higher level of performance and productivity of system with
high quality products at minimum cost.

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13. REFERENCES

[1] M. Dudek-Burlikowska*, D. Szewieczek , “The Poka-Yoke method as an improving quality

tool of operations in the process”; Journal of Achievements in Materials and Manufacturing
Engineering VOLUME 36 ISSUE 1 September 2009
[2] Anil S. Badiger, R. Gandhinathan, V. N. Gaitonde, Rajesh S. Jangaler “Implementation of
Kaizen and Poka-yoke to Enhance Overall Equipment Performance - A case study”

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