Poka-Yoke (Mistake-Proofing)

Poka-yoke is designing a process or device so that errors are impossible or immediately obvious — a connector that only fits one way, a sensor that blocks the next step if one is missed. It prevents defects at source rather than relying on inspection.

Mistake-proofing builds in physical or procedural safeguards so the human or machine simply cannot make (or cannot continue after) a common error. Examples include fixtures that reject mis-oriented parts, interlocks, checklists enforced by software and warning sensors. Because it stops defects being created at all, poka-yoke is far cheaper and more reliable than catching them in later inspection.

Related terms

Jidoka · Lean Manufacturing · Predictive Quality · Six Sigma

Where this applies

Improving first-pass yield · Implementing a line-clearance procedure · Rolling out mistake-proofing (poka-yoke)