Poka Yoke
The Japanese expression Poka Yoke ( Japanese ポ カ ヨ ケ , dt. "Avoid unfortunate mistakes") describes a principle consisting of several elements, which includes technical precautions or facilities for immediate error detection and prevention. Shigeo Shingō is considered to be the inventor of the principle .
Poka Yoke, as an error-avoiding principle, is similar to the biochemical key-lock principle , which has the effect of minimizing errors when duplicating genetic information, for example.
Surname
Poka denotes a wrong move in Go or Shogi and in a broader sense "stupid mistakes, blunders" in general. yoke comes from the verb yokeru , which means “avoid” in German.
method
The starting point for Poka Yoke is the knowledge that no person or system is able to completely avoid unintentional mistakes. With Poka Yoke, simple and effective systems are usually used to ensure that incorrect actions in the manufacturing process do not lead to errors in the end product. Poka Yoke aims to use mostly technical aids. These solutions are usually inexpensive and can be implemented immediately. It should be noted, however, that the causes of errors often lie in an earlier stage of the product development process and can be prevented there with significantly less effort.
Poka Yoke is used in conjunction with an inspection method, the source inspection, in order to be able to rule out a further occurrence of defects that have been discovered. Poka-Yoke in combination with the source inspection result in the method of the Poka-Yoke system.
Examples
- Acetylene cylinders have a unique clip connection to prevent dangerous confusion with other gases.
- Depending on the voltage and frequency, CEE plugs have different colors and contact arrangements to avoid mix-ups. This means that, for example, a 16 A plug cannot be inserted into a 32 A socket.
- Depending on the current work plan , only the appropriate component compartments are opened.
- TAE telephone plugs cannot be inserted upside down.
- In Germany, ATMs only issue money once the card has been withdrawn. This prevents you from forgetting the card.
- Due to their shape, SIM cards can only be inserted in the correct orientation in the SIM card slot.
- Position sensors on a press do not allow the pressing process to start until the component has been correctly inserted.
- Query eye color in forms for customer service representatives to ensure eye contact with the customer.
- Query of the shopping trolley number located above the rollers at the supermarket checkout in order to force the cashier to look at the lower shelf of the trolley.
history
For Shigeo Shingo, the starting point for the development of the Poka-Yoke system with source inspection was the statistical quality control (SQC). However, he stated: "Errors are created in the work phase, and tests cannot do anything other than find the errors."
The Toyota Production System (TPS), of which Poka Yoke is an integral part, is considered to be the key to the Japanese automotive company's market success.
See also
- quality control
- Jidōka
- Quality Gate - points in the course of a development project at which a decision is made on the approval of the next project step on the basis of clearly defined quality criteria in advance
literature
- Jochen Peter Sondermann, Gerd F. Kamiske (eds.): Poka Yoke. Carl Hanser Verlag, Munich 2013, ISBN 978-3-446-43569-8 .
- Jürgen P. Bläsing (ed.), Helmut Bayer, Tobias Bläsing: Poka Yoke: Zero errors are possible. Design robust processes with Poka Yoke methods. TQU Verlag, Ulm 2009.
- Nikkan Kōgyō Shimbun (Ed.): Poka-Yoke. Improving Product Quality by Preventing Defects. Productivity Press, Cambridge 1988, ISBN 0-915299-31-3 .
- Shigeo Shingō : Zero Quality Control: Source Inspection and the Poka-yoke System. Productivity Press, Cambridge 1986, ISBN 0-915299-07-0 .
- Gerd F. Kamiske , Jörg-Peter Brauer: Quality management from A to Z. Explanations of modern terms of quality management. Carl Hanser Verlag, Munich 2006, ISBN 3-446-40284-5 .