What is Poka-Yoke?
Poka-Yoke means mistake proofing.
It is a method used to prevent errors before they happen.
The main aim is simple: Do not allow mistake to occur
👉 If mistake happens, catch it immediately
Why Poka-Yoke is Important?
In production, small mistakes can create:
Rework
Rejection
Customer complaints
Extra cost
Poka-Yoke helps to avoid all these problems.
Simple Examples of Poka-Yoke
Mobile charger fits only in correct direction
Washing machine does not start if door is open
Fixture designed so part fits only one way
Sensor stops machine if part is missing
These are daily life examples, but same logic is used in factories.
Benefits of Poka-Yoke
Reduces human error
Improves product quality
Saves time and cost
Builds customer trust
Makes process safe and stable
Final Words
Poka-Yoke is not costly or complex.
It is about thinking smart and designing process in right way.
If process is right, quality will come automatically.
This concept is very useful for: Production engineers, Quality engineers, Supervisors, and Operators.
