Poka Yoke - Mistake Proofing

Poka Yoke is about the prevention and elimination of the possibility of mistakes.  Poka Yoke is a Japanese term that means “mistake-proofing.” Poka Yoke is a Lean Six Sigma technique.  Poka Yoke refers to mechanisms used in lean manufacturing processes to help prevent mistakes from occurring, thus ensuring high-quality production and reducing defects. Poka Yoka was developed by Shigeo Shingo in the 1960s as part of the Toyota Production System, this method has become an integral tool in modern manufacturing.

Poka Yoke, and other such Lean Six Sigma techniques, principles, and practices can also be used in accounting processes and in the creation of software tools.

Poka Yoke is a powerful quality control technique that helps prevent errors and mistakes.  Errors are made noticeable so that they can be corrected or impossible.  It helps improved efficiency and reduce costs.

Poka Yoke is about investing in building systems where errors do not occur because the cost of prevention is far less than the cost of remediation or cost of failure.  Poka Yoke is about moving from sigma level 3 where you are experiencing a quality level of about 93.7% or 66,807 defects per million opportunities to prevent defects to a sigma level 6 where you are experiencing a quality level of about 99.99966% or 4 defects per mission opportunities to prevent defects.

Yes, you are hearing me right: 66,807 defects down to 4.  This takes a lot of work, but it is worth the investment.

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