General Information
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Human mistake: 77.8%
General Information
Poka Yokes ensure that the right conditions exist before a process step is executed, and thus preventing defects from
occurring in the first place. Where this is not possible, Poka Yokes perform a detective function, eliminating defects
in the process as early as possible.
Poka Yoke is any mechanism in a Lean manufacturing process that helps to avoid mistakes.
Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they
occur.
POKA YOKE :
A poka-yoke is any mechanism in any process that helps an equipment operator avoids mistakes. Its purpose
is to eliminate product defects by preven ng, correc ng, or drawing a en on to human errors as they occur.
Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an
error can be made. For example, a #xture that holds pieces for processing might be modi#ed to only allow
pieces to be held in the correct orienta on, or a digital counter might track the number of spot welds on each
piece to ensure that the worker executes the correct number of weld
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QC & test
SOP
Mistake proof
0
%
The defect could be decreased to ZERO by
applying mistake proof properly.
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Type 1: zero accident but the
investment is higher than other types.
Type 2: Accident can happen if driver
didn’t notice the red light, investment
is less than type 1.
Type 3: it’s only one reminding to bus
driver, investment is less than type 1 &
2.
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Mistake proof on elastic band broken
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Mistake proof
for packing
errors
To detect leg in or
out automatically
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Automatic Elastic
band machine
(cutting & sewing)
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Wrong size
• Double check in Dry room
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To avoid
packing
errors by
control label
& tag QTY
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Mold prevention
Automatic dehumidifier
Alarm system while humidity
is exceed the above limit.
Manual check by Aqua boy.
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Broken needle control
Broken needle control
ND reject if any broken needle
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Sewing Mistake Proof
General Information
Thanks!