Toyota Production System Concepts - Poka Yoke - Design for Great Quality #742809

Poka-yoke, a Japanese term meaning "error-proofing", is a simple yet powerful technique used in lean manufacturing and quality management to prevent mistakes before they happen. These mistake-proofing devices help workers avoid errors such as using the wrong parts, forgetting steps, or assembling components incorrectly. In Japanese, "poka" means accidental mistake, and "yoke" means prevention or avoidance—together, poka-yoke ensures consistent quality in every process.

Have you ever wondered why Japanese cars are renowned for reliability? Even vehicles 20 years old can perform as well as the newest models in the automotive industry. The secret lies in building quality into the design and manufacturing process. By applying poka-yoke principles, companies create high-quality, defect-free products while reducing waste, improving efficiency, and supporting continuous improvement (kaizen).

This book provides practical examples of error-proofing techniques, showing how lean practitioners, quality engineers, and operations managers can implement poka-yoke in manufacturing, production, and service processes to achieve world-class quality and operational excellence.