What is Poka-Yoke in Manufacturing?

Poka-yoke, which is pronounced as poh-kah yoh-keh, is a Japanese word that translates to error-proofing. The word poka-yoke was invented in the 1960s in Japan by an industrial engineer known as Shigeo Shingo. Industrial engineers used the poka-yoke techniques in the Toyota production system to eliminate errors, but what is Poka-yoke in manufacturing, exactly?

Poka-yoke is a technique that eliminates errors in the manufacturing process. Initially, the technique was known as baka-yoke, which loosely translates to idiot- or fool-proofing. The term evolved from baka-yoke to poka-yoke, and it stuck. There are many practical uses of poka-yoke in general work, but it also comes in handy when manufacturing cables and wires.

Why is Poka-Yoke Important?

Errors are bound to happen during a production process because of human error. Poka-yoke is one of the techniques of lean manufacturing that ensure that products are in perfect condition. Clients are never happy to receive defective goods, and some even return the whole batch when they find a single defective unit.

Poka-yoke ensures the elimination of errors in the manufacturing process and acts as part of quality control in the manufacturing industry. Some of the products manufactured by Geospace Technologies are used in industries with sensitive manufacturing needs, including the military, home appliance, and automotive industries.

Manufacturing processes that use poka-yoke get the products right the first time, reducing the cost of trial-and-error. The results of these processes are high-quality and reliable because there are no defects.

Manufacturers can use poka-yoke techniques to improve product design and manufacturing processes of a product. In addition, the continuous refining process eliminates human and mechanical defects that occur throughout the production process.

Above all, poka-yoke is a flexible technique that makes it cost-effective for manufacturers who use it as part of their mistake-proofing activities. Therefore, manufacturers can prevent manufacturing errors at a small cost. Error-proofing allows manufacturers to increase the quality of their products at an insignificant cost.

Types of Poka-Yoke Devices

Several categories of poka-yoke devices are used in the manufacturing industry to prevent the production of defective products. A poka-yoke device can be a small plugin to prevent product misuse or something in the manufacturing process that prevents defects. The three categories include contact, fixed value, and motion step methods.

Contact Method

The contact method prevents errors in manufacturing processes by making physical contact with the product. The contact method uses various prevention measures depending on the manufacturing activities and the end product.

One of the prevention measures is the use of limit switches that are activated when a machine comes into contact with a cable or wire. Limit switches ensure that holes are driven to the ideal depth. Another method is the use of electrodes to identify conductive parts through contact. The circuit becomes complete when the electrodes touch a conductive material.

It is also imperative for error detection to happen during the error-proofing process. Some tactics used to detect errors are sensors and part bins. Part bins ensure all the parts of a product are available at the assembly station before they are put together. Additionally, manufacturers can use sensors to detect products that are overweight, underweight, bigger, or smaller than the product specifications.

Fixed Value Method

The method dictates that a product should have a constant number of components, materials, or inspections to meet the error-prevention standards. Therefore, manufacturers must ensure they check the fixed values of a product before giving it the thumbs up.

Manufacturers use dispensers to ensure a consistent number of parts is placed in part bins. Also, some manual controllers can stop conveyor belts when fixed values are not fulfilled during a process step. Therefore, errors are identified and rectified early on in the production process to ensure high-quality final products.

Another way manufacturers can identify errors in a system is by triggering alarms that send out an alert once a fixed value isn’t fulfilled. The alerts minimize the margin of error when manufacturers are producing large batches.

Motion/Step Method

The motion/step method ensures that there are checks across every processing step to identify errors in advance. The prevention of errors includes timing processes, numbering parts, creating clear workstation instructions, and conducting multiple checks after each process.

The final products will have all the required components, and any faulty products or parts will be disposed of during the production process. The motion/step method ensures that each production step is followed correctly for excellent results.

Everyday Applications of Poka-Yoke

• Manufacturers use poka-yoke to ensure that the washing machine door can open in the middle of the cycle.
• Automotive manufacturers use the technique to ensure fuel tanks don’t leak.
• The passenger seat of a car uses sensors to identify when there is a passenger and whether or not they’re wearing a seatbelt before sending out an alert.

What is Poka-Yoke in Manufacturing of Cables and Wires?

The error-prevention method ensures that wires and cables have the correct diameter and strength that match the plans. It also ensures that the end product is reliable in constructing durable electrical parts for various industry uses.

Wires and cables are a crucial part of electronics today, and any production error can lead to electronic device failure. Geospace Technologies uses various poka-yoke techniques to ensure the production of top-notch wires and cables for our clients. We understand the sensitive uses of wires and cable in electrical parts and take precautions to minimize human and mechanical errors.

The #1 Trusted Wire & Cable Manufacturers—Geospace Technologies 

With a combination of poka-yoke practices and automated processes, we strive to make all products right the first time. In addition, we deploy a variety of tests and inspection strategies to ensure nothing is missed. So you can rest easy knowing that a team of the best error-prevention experts is working on your design and process steps to ensure everything works out perfectly.

At Geospace Technologies, we pride ourselves on our excellent track record of producing high-performance wires and cables in the U.S.A. Our expert team is the #1 trusted manufacturer for all your wire and cable manufacturing needs. Now that you know the answer to your question, what is poka-yoke in manufacturing, reach out to our dedicated customer support team if you’re interested in requesting a quote for your manufacturing needs, and we look forward to working with you!