Poka-Yoke: Improving Product Quality by Preventing Defects, 1st Edition (Hardback) book cover


Improving Product Quality by Preventing Defects, 1st Edition

By Nikkan Kogyo Shimbun

Productivity Press

298 pages

Purchasing Options:$ = USD
Hardback: 9780915299317
pub: 1989-02-01

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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.)

Table of Contents

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


Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Business Communication / General
BUSINESS & ECONOMICS / Quality Control