What is Poka-Yoke?

It is the practice of designing work to reduce predictable errors.
It does not rely on extra attention.
Nor on constant effort.

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It starts from the understanding that error is not an exception.
It is part of human functioning and needs to be anticipated.

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Instead of correcting later, poka-yoke acts earlier.

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It adjusts the way work is done so the error does not move forward.

 

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How it shows up in practice​

It appears in simple details.

In physical limits.
In objects that guide the gesture.

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It shows up when something fits only one way.
When an out-of-pattern action is blocked by the design itself.
When the flow leads naturally to the next correct move.

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Poka-yoke does not draw attention to error.
It reduces the chance that error happens.

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Examples 

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- A microwave does not run with the door open.

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- A form does not proceed with required fields left blank.

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- An order does not move forward without minimum information.​

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- A piece of equipment fits only in the correct position.

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Everyday principles

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Prevention before correction
The focus is not on training more or demanding attention.
It is on adjusting work to reduce predictable failures.

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Human error is expected
People get distracted, tired, and interpret things differently.
Poka-yoke takes this as a given.

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The process protects the personI
nstead of relying on memory, the way work functions guides the right action.

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Simplicity
Solutions are visual, physical, or logical.
The simpler, the better.

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Immediate detection
If something goes out of pattern, it shows up right away.

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Blocking or automatic adjustment
The system prevents incorrect progress or requires correction before continuing.

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Cause, not symptom
It is not a warning saying “pay attention.”
It is a change that removes repeated error.

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Why I brought this theme​

Many environments still treat error as individual failure.
More attention.
More care.
More pressure.

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Poka-yoke shifts this weight. 
It shows that protecting work is also protecting the people who do the work.

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When error no longer depends on memory, everyday work becomes lighter. And functioning becomes more reliable.

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Questions to keep with you

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✧ Where does work depend too much on attention or memory?

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✧ Which errors keep repeating?

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✧ What could be adjusted to reduce these failures?

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To go further​​

▷ What is Poka-Yoke?

▷ Poka-Yoke example

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​← Back to Lean Six Sigma

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← Back to lab​​​​​​​​​​​​​​