The Two Directions of Poka Yoke

Poka yoke is Japanese for mistake proofing. It is a way to reduce errors and mistakes by designing the product so that it cannot be assembled or used incorrectly. I find this extremely useful, not only in manufacturing but also in many instances in daily life where poka yoke prevents me from making mistakes. In this post, I would like to talk about poka yoke, and the two fundamentally different directions poka yoke can take.

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Poka Yoke Training – Simple Mistake Proofing Game

Assembled Blue Dragon
Poka yoke anyone?

Mistake proofing (or Poka Yoke in Japanese) is one important way to avoid waste in lean manufacturing. In this post, I will present a small game that can be used to teach the basics of poka yoke easily and quickly. The game is based on Kinder Surprise eggs made by Ferrero, also known as a Kinder Egg. These eggs are available almost anywhere – except in the US, in which case there are some alternatives.

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On the Lean Guru Shigeo Shingo

Shigeo ShingoShigeo Shingo is a name that everyone in the United States lean community knows. He is sometimes considered “the world’s leading expert on manufacturing practices and the Toyota Production System,” an “engineering genius,” and the foremost guru of lean production. Some sources even claim he invented the Toyota Production System and taught Taiichi Ohno. Shingo greatly helped to popularize the idea of Lean in the USA. However, he invented much less than what is sometimes claimed, and there is also quite some disagreement in the lean community on this. Let’s have a look at his life and his achievements.

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