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In any improvement program error or mistake proofing is an important part of any defect reduction process.  As with many lean initiatives it’s origins are in the Automotive sector (Toyota to be precise)

By capturing and eliminating errors before the products proceed to the next step Poka yoke ensures that mistakes do not turn into defects.  At the heart of Poka Yoke is the use of visual controls which allow the workers to assess the quality of what is produced.  Simple methods of highlighting (and preventing defects) can be implemented using three types of inspection

* Judgement inspection – removing defects items from acceptable items
* Informative inspection – Workers assess and inspect the work of the previous process and provide feedback where errors are found.
* Source inspection – The business ensures that the environment is condusive to producing a quality product.

Poka Yoke is usually coupled with process analysis as the tool is best used as an improvement tool and therefore is best placed where existing defects occur and it can add most value.
Poka Yoke is simple, usually low cost and can help remove defects at source Poka Yoke is very common (partly due to its simplicity) – as individuals we come across forms of it in our everyday lives – from pink paint that dries white (allowing for the decorator to see the area covered) through to petrol caps with the type of fuel required written on it.

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