Why do you need this service?
Poka-Yoke Training teaches teams to design simple safeguards that prevent an error or detect it immediately where it occurs. The method reduces dependence on final inspection, operator memory and warnings alone, supporting quality at source.
When does Poka-Yoke provide the most value?
- assembly or order-picking errors recur regularly,
- a non-conformity is detected only at the end of the process or by the customer,
- work involves many variants and manual decisions,
- inspection takes time but does not remove the cause of the error,
- the organisation wants to connect Kaizen, FMEA and standardised work.
The workshop supports the Kaizen system and quality system requirements. We design solutions with the people doing the work, because they know the actual process conditions best.
What is our role?
We work at the Gemba: observing the process, analysing error types, their effects and causes, then guiding the team through generating and evaluating safeguard concepts. We prioritise solutions that are simple, reliable, easy to check and maintainable.
We can combine Poka-Yoke Training with FMEA, problem solving and TWI. After selecting a solution, we support prototyping, testing, updating standard work and preparing operators and leaders.
Workshop outcomes
- a list of priority errors and their mechanisms,
- concepts for preventive and detection safeguards,
- test criteria and confirmation of effectiveness,
- a standard for checking Poka-Yoke operation,
- an implementation and scaling plan.
A handful of facts
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mechanisms: prevention and detection
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stages of solution testing through PDCA
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goal: quality at the source of the process
Implementation support
We provide support based on the Kata process, which allows us to adapt our activities to the specifics of your organization, taking into account the jointly set goals. The Kata process consists of four key elements that enable effective implementation of assumptions.
We operate according to PDCA
P
PLAN
PLAN — risk and the purpose of the safeguard
We select a process and an error with a significant impact on the customer, safety, cost or flow. We analyse quality data, observe work and use FMEA and problem-solving logic. We establish whether the safeguard should prevent the error or detect it before it is passed on.
- selection of a critical problem,
- description of the error mechanism and the conditions in which it occurs,
- assessment of existing controls,
- effectiveness and reliability criteria,
- a prototype plan and responsibilities.
D
DO
DO — design and prototype
The team develops concepts using shape, sequence, position, quantity, a sensor, an interlock or a simple signal. We build a prototype as quickly as practicable and test it within the actual work cycle, with operators involved.
- generating several solution options,
- assessing simplicity, cost and robustness,
- building a prototype,
- testing correct and incorrect scenarios,
- updating instructions and training users.
C
CHECK
CHECK — effectiveness under process conditions
We check whether the safeguard works across all variants, shifts and typical disturbances. We measure the number of errors, process response, false alarms and the ease of daily checks. We collect feedback from operators and maintenance.
- boundary-condition tests,
- comparison of quality before and after,
- checks for bypassing or disabling the safeguard,
- assessment of the impact on cycle time and ergonomics,
- a list of necessary adjustments.
A
ACT
ACT — standard, monitoring and rollout
Once effectiveness has been confirmed, we incorporate the solution into the process standard. We define the daily check, the response to a failure and the owner. We transfer effective safeguards to similar products, workstations and processes.
- approval of the Poka-Yoke standard,
- a plan for checking that the device works,
- response to a malfunction or deviation,
- updates to FMEA and the Control Plan,
- rollout and a library of good practices.
Want to learn more? Contact us!
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