Smart as a 5th grader, you can implement Poka-Yoke

These are the the tools I use for Poka-Yoke Implementation. It will make you as “Smart as a 5th Grader.” Yes, this is not rocket scientist stuff. It is easy and simple. Now, these methods alone will not get you to Six Sigma Quality levels but they will start you on the path of continuous and measured improvement. So what are the tools?

The first tool I use may not be considered a tool at all, it is a mind set, This is NOT WHAT to DO. I keep this diagram around and embed it in most of things that are printed. It is very simple but the key to making a successful Poka-Yoke campaign.

The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.

Organize your mistakes(errors) and group them according to the Matrix. This will simplify the selection process on what mistake to tackle first.

I also have a list of Common Red Flag Conditions. These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first “WHY” in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing.

1. Frequent changes to a job
2. Complex processes
3. Lack of Standards
4. Lack of measurement systems
5. Lack of training
6. Long cycle times
7. Infrequent jobs
8. High output
9. Environmental conditions
10. Attitude ( Motivation)

The one tool that I have left is the project sheet. We will start completing the components of this in the next blog and create a Poka-Yoke process in it’s entirety.

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