Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. For example, a fixture that holds pieces for processing might be modified to only allow pieces to be held in the correct orientation, or a digital counter might track the number of spot welds on each piece to ensure that the worker executes the correct number of welds.

Three types of poka-yoke for detecting and preventing errors in a mass production system

  1. The contact method identifies product defects by testing the product’s shape, size, color, or other physical attributes.

Three-step analysis of the risks to be managed

  1. Identification of the need
  2. Identification of possible mistakes
  3. Management of mistakes before satisfying the need