Mistake Proofing Concepts and Practices

Mistake proofing, or poke yoka, aims for zero defects by preventing and detecting errors. It requires a shift from accepting human fallibility to finding ways to prevent mistakes. Companies using this method adopt a no-blame policy, encouraging error reporting. The process involves identifying errors, understanding their causes, and preventing recurrence. Mistake proofing devices range from simple checklists to sophisticated alarms, ensuring correct procedures and placements.

Who is credited with practicing mistake proofing (Poka-Yoke)?

• Dr. Taiichi Ohno

• Dr. Joseph Juran

• Dr. Shago Shingo

• Dr. Edward Deming

What is the primary goal of mistake proofing?

• To reduce costs

• To increase production speed

• To reach zero defects

• To improve employee satisfaction

What is the first basic way mistake proofing is used?

• To improve product design

• To train employees better

• To prevent errors from occurring

• To detect errors after they occur

What does striving for zero defects require?

• More employee training

• A change in traditional thinking

• Better quality materials

• An increase in production

What policy do companies that use mistake proofing successfully operate under?

• Strict punishment

• No blame

• Increased supervision

• Higher wages

What is the first step in the mistake proofing process?

• Implementing new technology

• Identifying if an error has occurred

• Training employees

• Changing the production process

Which of the following is NOT one of the three key questions in the mistake proofing process?

• Has an error occurred?

• Why did it occur?

• Who is responsible?

• What is the best way to prevent it from occurring again?

What is the purpose of guide pins and rails in mistake proofing?

• To count events

• To alert workers

• To ensure proper alignment

• To detect errors

What is the simplest mistake proofing device mentioned?

• Printed checklists

• Counters

• Limit switches

• Error detection alarms

What is the function of error detection alarms in mistake proofing?

• To alert workers of errors

• To ensure proper alignment

• To display checklists

• To count events