Ultimately, every business will incur non-conformance, either internally within the Organisation or externally with customers. These non-conformances should be valued against a risk of repetition and ultimately decided whether this is a risk that the business can accept or wont accept.

There are 4 main types of risk management strategy:

1.     Reduce,

2.     Transfer,

3.     Avoid, or

4.     Accept

When we consider reducing our exposure to the risk a particular issue may present, we may consider a ‘poke-yoke’.

A poke-yoke (poh-ka-yoh-keh) is a term coined by Toyota which means to mistake proof, or literally, to avoid errors.

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A poke yoke is any mechanism placed into a process that helps to avoid mistakes.

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There are 2 types of Poke Yoke:

1.     Shut Out: This type physically prevents an error being made.

2.     Raise Attention: This type highlights that an error has been made and requires assistance.

Shut Out is the most preferable method as this completely eradicates the error from happening.

As an example, it was a common issue was to put the wrong type of fuel into your car; diesel into a petrol car and petrol into a diesel car. Overtime, both the car manufacturers and petrol stations have moved to eradicate this issue by increasing the diameter of the nozzle neck and the opening in the car for diesel vehicles. This has meant that the diesel nozzle will not not fit into a petrol vehicle and thus far less likely to put diesel into a petrol car. It doesn’t stop putting petrol into a diesel car but the outcome inhibits far less damage to the car.

An attention type is where there are usually signals, such as noise or light to draw attention to the issue in hand. For example, large vehicles now have reversing beeps or the lights at a self service in the supermarket when something has not gone correctly.

These poke-yoke are inexpensive, simple and easy to implement and can be developed by every employee.

Are you improving your non-conformances through Poke Yokes?  

Connect with Noon Edwards today to see how we can help you with your Lean Six Sigma journey.

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