{"id":20653,"date":"2022-05-19T17:47:05","date_gmt":"2022-05-19T21:47:05","guid":{"rendered":"https:\/\/www.lean.org\/?post_type=glossary&#038;p=20653"},"modified":"2022-05-19T17:47:07","modified_gmt":"2022-05-19T21:47:07","slug":"poka-yoke","status":"publish","type":"glossary","link":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/","title":{"rendered":"Poka Yoke"},"content":{"rendered":"\n<p>Poka-yoke is a Japanese term that means &#8220;error-proofing&#8221; by implementing simple and inexpensive devices that help operators avoid mistakes in their work caused by the wrong parts, leaving out a part, installing a part backwards, <em>etc<\/em>. In Japanese, \u201cPoka\u201d means inadvertent error, and \u201cyoke\u201d means prevention.<\/p>\n\n\n\n<p>The purpose of poka-yoke is to achieve 100% quality by finding defects at their source. This prevents an operator from passing on defects and enables the team to problem-solve so the defect stops recurring. In contrast, quality by sampling inspection guarantees defects because samples of parts or products will not always contain defects that exist in total production. And quality by 100% inspection is not only costly but finds defects from their source, which makes it difficult to permanently eliminate their cause.<\/p>\n\n\n\n<p>There are two types of poka-yoke: <\/p>\n\n\n\n<ol><li><strong>Shutdown<\/strong>: These are the most powerful error- proofing devices. For example, a machine will not start if a work piece is set incorrectly.<\/li><li><strong>Warning<\/strong>: These alert us to something abnormal by a buzzer or light.<\/li><\/ol>\n\n\n\n<p>Good poka-yoka meet the following criteria: <\/p>\n\n\n\n<ul><li>simple, with long life and low maintenance\u00a0bHas high reliability<\/li><li>inexpensive<\/li><li>designed for the workplace situation<\/li><\/ul>\n\n\n\n<p>Common examples of error-proofing include:<\/p>\n\n\n\n<ul><li>Product designs with physical shapes that make it impossible to install parts in any but the correct orientation.<\/li><li>Photocells above parts containers to prevent a product from moving to the next stage if the operator\u2019s hands have not broken the light to obtain necessary parts.<\/li><li>A more complex parts monitoring system, again using photocells, but with additional logic to make sure the right combination of parts was selected for the specific product being assembled.<\/li><\/ul>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Common Examples of Poka Yoke in Every Day Life<\/h2>\n\n\n\n<div style=\"height:27px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<ul><li>Blind spot warning in a vehicle to prevent accidents<\/li><li>Auto-stop function on a table saw to prevent injury<\/li><li>Spell-check in a word processor to prevent spelling and grammar mistakes<\/li><li>Auto-brake in vehicles to prevent collisions<\/li><li>Washing machines will not start until the door has closed and will stop if opened mid-cycle <\/li><li>Lawn mowers will operate only when a safety bar is held down and will switch off when released <\/li><\/ul>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Additional Resources<\/h2>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:33% auto\"><figure class=\"wp-block-media-text__media\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/why-create-poka-yokes-and-why-disconnect-them\/\" target=\"_blank\" rel=\"noopener\"><img loading=\"lazy\" decoding=\"async\" width=\"820\" height=\"644\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg\" alt=\"Factory\" class=\"wp-image-20109 size-full\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg 820w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-300x236.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-768x603.jpg 768w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-150x118.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-375x295.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-190x149.jpg 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk-600x471.jpg 600w\" sizes=\"(max-width: 820px) 100vw, 820px\" \/><\/a><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/why-create-poka-yokes-and-why-disconnect-them\/\" target=\"_blank\" rel=\"noreferrer noopener\">Why Create Poka-yokes\u2014and Why Disconnect Them?<\/a><\/h3>\n<\/div><\/div>\n\n\n\n<div style=\"height:28px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:33% auto\"><figure class=\"wp-block-media-text__media\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/properly-applying-auto-eject-isnt-automatic\/\" target=\"_blank\" rel=\"noopener\"><img loading=\"lazy\" decoding=\"async\" width=\"820\" height=\"640\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4.jpg\" alt=\"Hands moving blocks on a wooden table.\" class=\"wp-image-20340 size-full\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4.jpg 820w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-300x234.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-768x599.jpg 768w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-150x117.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-375x293.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-190x148.jpg 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_4-600x468.jpg 600w\" sizes=\"(max-width: 820px) 100vw, 820px\" \/><\/a><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/properly-applying-auto-eject-isnt-automatic\/\" target=\"_blank\" rel=\"noreferrer noopener\">Properly Applying Auto-Eject Isn\u2019t Automatic<\/a><\/h3>\n<\/div><\/div>\n\n\n\n<div style=\"height:28px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-media-text alignwide is-stacked-on-mobile\" style=\"grid-template-columns:33% auto\"><figure class=\"wp-block-media-text__media\"><a href=\"https:\/\/www.allaboutlean.com\/poka-yoke-training\/\" target=\"_blank\" rel=\"noopener\"><img loading=\"lazy\" decoding=\"async\" width=\"820\" height=\"640\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3.jpg\" alt=\"Executive tripping over a hurdle bar.\" class=\"wp-image-20337 size-full\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3.jpg 820w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-300x234.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-768x599.jpg 768w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-150x117.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-375x293.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-190x148.jpg 190w, https:\/\/www.lean.org\/wp-content\/uploads\/2022\/05\/Hoshin_3-600x468.jpg 600w\" sizes=\"(max-width: 820px) 100vw, 820px\" \/><\/a><\/figure><div class=\"wp-block-media-text__content\">\n<h4 class=\"wp-block-heading\">Article<\/h4>\n\n\n\n<h3 class=\"wp-block-heading\"><a href=\"https:\/\/www.allaboutlean.com\/poka-yoke-training\/\" target=\"_blank\" rel=\"noreferrer noopener\">Poka Yoke Training \u2013 Simple Mistake Proofing Game<\/a><\/h3>\n<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Poka-yoke is a Japanese term that means &#8220;error-proofing&#8221; by implementing simple and inexpensive devices that help operators avoid mistakes in their work caused by the wrong parts, leaving out a part, installing a part backwards, etc. In Japanese, \u201cPoka\u201d means inadvertent error, and \u201cyoke\u201d means prevention. The purpose of poka-yoke is to achieve 100% quality [&hellip;]<\/p>\n","protected":false},"author":23,"featured_media":0,"menu_order":0,"comment_status":"open","ping_status":"closed","template":"","meta":{"_acf_changed":false,"_relevanssi_hide_post":"","_relevanssi_hide_content":"","_relevanssi_pin_for_all":"","_relevanssi_pin_keywords":"","_relevanssi_unpin_keywords":"","_relevanssi_related_keywords":"","_relevanssi_related_include_ids":"","_relevanssi_related_exclude_ids":"","_relevanssi_related_no_append":"","_relevanssi_related_not_related":"","_relevanssi_related_posts":"11970,5795,6903,8724,7313,13444","_relevanssi_noindex_reason":"","footnotes":""},"glossary-categories":[],"glossary-tags":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.9 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Poka Yoke - A Resource Guide | Lean Enterprise Institute<\/title>\n<meta name=\"description\" content=\"Poka yoke is a Japanese term that means &quot;error-proofing&quot; by implementing simple devices that help operators avoid mistakes in their work.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.lean.org\/lexicon-terms\/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 - A Resource Guide | Lean Enterprise Institute\" \/>\n<meta property=\"og:description\" content=\"Poka yoke is a Japanese term that means &quot;error-proofing&quot; by implementing simple devices that help operators avoid mistakes in their work.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/\" \/>\n<meta property=\"og:site_name\" content=\"Lean Enterprise Institute\" \/>\n<meta property=\"article:modified_time\" content=\"2022-05-19T21:47:07+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"3 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/\",\"url\":\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/\",\"name\":\"Poka Yoke - A Resource Guide | Lean Enterprise Institute\",\"isPartOf\":{\"@id\":\"https:\/\/www.lean.org\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage\"},\"image\":{\"@id\":\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg\",\"datePublished\":\"2022-05-19T21:47:05+00:00\",\"dateModified\":\"2022-05-19T21:47:07+00:00\",\"description\":\"Poka yoke is a Japanese term that means \\\"error-proofing\\\" by implementing simple devices that help operators avoid mistakes in their work.\",\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage\",\"url\":\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg\",\"contentUrl\":\"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg\",\"width\":820,\"height\":644},{\"@type\":\"WebSite\",\"@id\":\"https:\/\/www.lean.org\/#website\",\"url\":\"https:\/\/www.lean.org\/\",\"name\":\"Lean Enterprise Institute\",\"description\":\"Lean Production | Lean Manufacturing | LEI | Lean Services\",\"publisher\":{\"@id\":\"https:\/\/www.lean.org\/#organization\"},\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\/\/www.lean.org\/?s={search_term_string}\"},\"query-input\":\"required name=search_term_string\"}],\"inLanguage\":\"en-US\"},{\"@type\":\"Organization\",\"@id\":\"https:\/\/www.lean.org\/#organization\",\"name\":\"Lean Enterprise Institute\",\"url\":\"https:\/\/www.lean.org\/\",\"logo\":{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\/\/www.lean.org\/#\/schema\/logo\/image\/\",\"url\":\"https:\/\/www.lean.org\/wp-content\/uploads\/2020\/07\/lei_logo.jpg\",\"contentUrl\":\"https:\/\/www.lean.org\/wp-content\/uploads\/2020\/07\/lei_logo.jpg\",\"width\":1500,\"height\":450,\"caption\":\"Lean Enterprise Institute\"},\"image\":{\"@id\":\"https:\/\/www.lean.org\/#\/schema\/logo\/image\/\"}}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Poka Yoke - A Resource Guide | Lean Enterprise Institute","description":"Poka yoke is a Japanese term that means \"error-proofing\" by implementing simple devices that help operators avoid mistakes in their work.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/","og_locale":"en_US","og_type":"article","og_title":"Poka Yoke - A Resource Guide | Lean Enterprise Institute","og_description":"Poka yoke is a Japanese term that means \"error-proofing\" by implementing simple devices that help operators avoid mistakes in their work.","og_url":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/","og_site_name":"Lean Enterprise Institute","article_modified_time":"2022-05-19T21:47:07+00:00","og_image":[{"url":"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg"}],"twitter_card":"summary_large_image","twitter_misc":{"Est. reading time":"3 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"WebPage","@id":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/","url":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/","name":"Poka Yoke - A Resource Guide | Lean Enterprise Institute","isPartOf":{"@id":"https:\/\/www.lean.org\/#website"},"primaryImageOfPage":{"@id":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage"},"image":{"@id":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage"},"thumbnailUrl":"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg","datePublished":"2022-05-19T21:47:05+00:00","dateModified":"2022-05-19T21:47:07+00:00","description":"Poka yoke is a Japanese term that means \"error-proofing\" by implementing simple devices that help operators avoid mistakes in their work.","inLanguage":"en-US","potentialAction":[{"@type":"ReadAction","target":["https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/"]}]},{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/www.lean.org\/lexicon-terms\/poka-yoke\/#primaryimage","url":"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg","contentUrl":"https:\/\/www.lean.org\/wp-content\/uploads\/2022\/04\/car-assembly-line-factory-production-line-clip-art-png-favpng-PLr9Pb5ASYBz7upbY6wfNF1rk.jpg","width":820,"height":644},{"@type":"WebSite","@id":"https:\/\/www.lean.org\/#website","url":"https:\/\/www.lean.org\/","name":"Lean Enterprise Institute","description":"Lean Production | Lean Manufacturing | LEI | Lean Services","publisher":{"@id":"https:\/\/www.lean.org\/#organization"},"potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/www.lean.org\/?s={search_term_string}"},"query-input":"required name=search_term_string"}],"inLanguage":"en-US"},{"@type":"Organization","@id":"https:\/\/www.lean.org\/#organization","name":"Lean Enterprise Institute","url":"https:\/\/www.lean.org\/","logo":{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/www.lean.org\/#\/schema\/logo\/image\/","url":"https:\/\/www.lean.org\/wp-content\/uploads\/2020\/07\/lei_logo.jpg","contentUrl":"https:\/\/www.lean.org\/wp-content\/uploads\/2020\/07\/lei_logo.jpg","width":1500,"height":450,"caption":"Lean Enterprise Institute"},"image":{"@id":"https:\/\/www.lean.org\/#\/schema\/logo\/image\/"}}]}},"_links":{"self":[{"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary\/20653"}],"collection":[{"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary"}],"about":[{"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/types\/glossary"}],"author":[{"embeddable":true,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/users\/23"}],"replies":[{"embeddable":true,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/comments?post=20653"}],"version-history":[{"count":4,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary\/20653\/revisions"}],"predecessor-version":[{"id":20657,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary\/20653\/revisions\/20657"}],"wp:attachment":[{"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/media?parent=20653"}],"wp:term":[{"taxonomy":"glossary-categories","embeddable":true,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary-categories?post=20653"},{"taxonomy":"glossary-tags","embeddable":true,"href":"https:\/\/www.lean.org\/wp-json\/wp\/v2\/glossary-tags?post=20653"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}