1st Edition

Poka-Yoke Improving Product Quality by Preventing Defects

By Nikkan Kogyo Shimbun Copyright 1989
    298 Pages
    by Productivity Press

    If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole.

    The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants.

    The book:

    • Organizes examples according to the broad issue or problem they address.
    • Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes.
    • Provides sample improvement forms for you to sketch out your own ideas.

    Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)

    Publisher's Foreword
    Overview of Poka-yoke
    240 Poka-Yoke Examples
    Processing Errors
    Assembly Errors
    Mounting Errors
    Inclusion of Wrong Items
    Insertion Errors
    Assembly Omissions
    Processing Omissions
    Measurement Errors
    Dimensional Errors
    Omissions of Operations
    Operations Errors
    Pasting/Labeling Errors
    Inspection Errors
    Wiring/Contact Errors
    Painting Errors
    Printing Errors
    Set-Up Errors
    Packing/Wrapping Errors
    Mismatched Jigs and Dies
    Rinsing Errors
    Miscellaneous Problems
    Improvement Form


    Nikkan Kogyo Shimbun