Poka Yoke, also known as “error-proofing systems”, offer innovative solutions that can revolutionize the production process. However, despite its potential, there is still a knowledge gap regarding the specific benefits this solution can bring.
In this article, we will not only explore the basic advantages of implementing Poka Yoke but also learn about management strategies that can ensure maximum benefits for the organization.
Poka Yoke – Error elimination at the early stage of production
The implementation of Poka Yoke on the production line enables the detection and elimination of errors at an early stage of the production process. As a result, discrepancies can be identified and corrected before they proceed to subsequent stages of production. This proactive strategy ensures that the final product will be free from defects and meet customer expectations.
Fig. 1. Poka Yoke finds frequent application in the manufacturing environment.
As easily observed, the implementation of Poka Yoke introduces control systems that minimize the risk of producing defective products. By employing preventive error-proofing solutions, the company can effectively prevent the occurrence of defects and discrepancies during production.
This, in turn, leads to a reduction in the number of 0-km complaints and warranty returns, as well as associated costs for repair or scrapping of non-conforming parts.
Improvement of company reputation and customer trust
Consistently striving for excellence in product quality through the implementation of Poka Yoke positively impacts the company’s reputation and builds customer trust. Why? Because our customers appreciate the high quality of products, which translates into building long-lasting business relationships and the opportunity to participate in new projects.
Ultimately, the organization gains a positive image in the market, which can lead to acquiring new business partners. Implementing Poka Yoke systems on the production line contributes, of course, to significant cost reduction in the company.
But how it could be achieved?
By avoiding defective products, the company saves time, resources, and finances on repairs and restarting production. This, of course, has a positive impact on the financial balance. Additionally, increasing the efficiency of the production process leads to increased profitability of the enterprise. This allows the organization to develop and compete more effectively in the market.
As we can see, in the long run, this is the key to achieving optimal performance and cost reduction.
Implementation is just the beginning, but what about assessment?
First and foremost, the evaluation and verification of new Poka Yoke systems should be conducted during the validation of equipment on the production line for the implementation of new projects.
This does not mean that such an assessment is performed only once. Why? Because we should conduct reassessment also in the following situations:
– Process change or physical change (or relocation) of an existing PY system
– Manufacturing of a new product or product change on an existing production line
– After implementing a new PY following a quality issue report.
– Transfer of equipment to another location
What else can initiate the implementation of Poka Yoke?
– Lessons learned from the previous project
– Read Across
– Customer complaint (zero-kilometer, warranty claim) or internal report and its outcome
– Result of root cause analysis in relation to human error
Example of the Poka Yoke system in action based on the use of photoelectric switches
Depending on the requirements, we can use photoelectric switches for translucent or transparent parts.
Transmission method – two units, one for transmitting (emitting) light, the other for receiving.
Fig. 2 Photoelectric switche as a Poka Yoke system reacts to light reflected from the object, detecting its presence. In this way, if a part interrupts the transmission, the machine receives a signal to shut down.
Poka Yoke – Summary
Implementing Poka Yoke on the production line doesn’t only invest in quality and efficiency but also in the future of every organization. By eliminating errors at an early stage of production, we achieve not only better product quality but also greater customer satisfaction and profits.
Other benefits are immeasurable, but it’s worth mentioning them:
– Effective Poka Yoke systems help employees perform tasks without frustration associated with production errors, which positively affects their motivation.
– They are usually easy to understand and operate, facilitating quick and effective training of new employees.
– Thanks to automatic error detection systems, employees can focus on monitoring and improving the production process rather than dealing with problems resulting from errors.
You are also warmly invited to participate in the “Error & Mistake Proofing – Effective Management” training.
Dariusz Kowalczyk
