WHAT IS POKAYOKE

POKAYOKE OR ERROR PROOFING (ポカヨケ)



















What is POKAYOKE ?
POKAYOKE is Japanese word which means error proofing.The POKAYOKE should be implemented in our process so that when the process is running there should be no chance of error.This is responsibility of process engineer that during development of tools,machines,process they should include error proofing mechanism by considering all possible combination of errors..


What happened due to lack of POKAYOKE ?
The error Proofing is very basic requirement of  industry as lack of error proofing may cause machine or products failure or also may cause high severe problems loss of revenue due to repeat issues, campaigns, and loss of customers, It also causes additional non-value added activities, expenses, and people costs.

As per AIAG Guidelines for effective Error-proofing .
with a goal of providing a comprehensive manual focused on manufacturing-based industries to achieve a “zero error” culture via the following:

• Focus on proactive error-proofing through both product and process design, and continual improvement activities.
• Elimination or significant reduction of process sensitivity due to variation (e.g., operator performance, tool wear, multiple machines, etc.).
•  Effective detection for errors that cannot be prevented.
• Subsequent error-proofing for problem elimination.
•  Control of detected errors/non-conforming product.
•  Deployment of error-proofing on similar operations (read across).
• Communication of best practices and prior experience to eliminate repeat issues
• Fully integrating error-proofing approaches with existing quality tools and procedures (APQP, FMEAs, Control Plans, etc.).
•  An assessment system for error-proofing.
• Appropriate monitoring and controls for installed error-proofing.
• Guidance fo layered process audits of error-proofing