Poka Yokes for Beginners

Poka yoke means "mistake proofing" or "error prevention", but what does that actually mean and how can it help us get better?

Poka yoke is a Japanese term that means “mistake proofing” or “error prevention”. It’s a method for creating or improving processes to reduce the chance of making mistakes or help you avoid simple human errors. Poka yoke can be used in any industry, but it was originally developed as a kay part of the Toyota Production System (TPS).

Poka yokes that apply to safety improvement can be implemented in different ways, including:

• Warning mechanisms alert operators to potential errors or defects, but they don’t automatically stop the process.
• Control mechanisms stop the process from moving to the next step until the proper conditions are met.

We benefit from poka yoke methodologies every day. How many of the following examples have your experienced today?

• Car safety features – Beeping when your seatbelt isn’t fastened; a light or notification when your gas tank is getting closer to empty; reverse camera with a sound when you get too close to an object.
• Treadmills – When the safety clip is pulled, the treadmill will not operate, protecting you if you fall.
• Household appliances – Microwaves, dishwashers, dryers and washing machines won’t operate until the door is closed.
• Elevators and garage doors – Most are equipped with a sensor that prevents the door from closing if there is something in the way.
• Spell-check function – Autocorrect or spell-check alert us to spelling and grammatical errors.
• Leak-proof water bottles and travel mugs – Drinkware that requires the user to press and hold a button in order to prevent the contents from leaking or spilling if it’s tipped over.
• Overflow outlets in sinks – Most sinks have a hole just below the edge of the bowl that prevents water from overflowing if the drain is blocked.
• Lawnmower safety bars – In the United States, lawnmowers are required to have a mechanism that must be engaged in order for the blades to move. This is usually the level attached to the handle that the operator must press in order for the lawnmower to run.
• Wheelchair wheels – These wheels are designed to lock when the chair isn’t in motion, ensuring the occupant doesn’t slip when getting in and out of the wheelchair.

Implementing poka yokes at work helps employees and businesses by reducing waste, improving efficiency, reducing costs and reducing our safety risks.

Join the Poka Yoke Contest by November 8!

We’re in our fourth year of recognizing the best of the best poka yokes with our Annual Poka Yoke Contest. There are four winning poka yokes, including Most Impactful Poka Yoke and Most Innovative Poka Yoke. All submitted poka yokes from December 2023 to November 8, 2024 will be entered into the contest. Learn more about the contest, prizes and previous winners in the contest launch article here.

And if you have any questions about the poka yoke process, please reach out to Bill Schuster, Regional SH&E Manager, at Bill.Schuster@olysteel.com.

Safety First. Always. And, it starts with me.