Quality poster
Updated · Free to print and share
Poka-yoke types poster
Poka-yoke means mistake-proofing: designing the work so a mistake cannot happen, or is caught the moment it does. Shigeo Shingo described three methods: contact (shape or size), fixed-value (a set count) and motion-step (a set sequence), and two functions: control devices that stop the process and warning devices that alert someone. This poster shows each with an everyday shop floor example.
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The words on the poster
Poka-yoke: mistake-proofing
Make the mistake impossible, or catch it the moment it happens.
Three methods
- Contact Shape or size detects the error. A part that fits only one way.
- Fixed-value A set count must be reached. A kit tray with one pocket per part.
- Motion-step Steps must happen in order. A sensor that checks the sequence.
Two functions
- Control Stops the process: the part won't fit, the machine won't start. Best.
- Warning Alerts with a light or sound. Works only if someone acts.
Methods and functions as described by Shigeo Shingo.
On the floor
How to use it
- 1
Put it in the engineering or CI area where error-proofing ideas are discussed.
- 2
Use it when a defect comes from a mistake: which method could prevent it?
- 3
Ask: can this warning device become a control device?
- 4
Pair it with the free poka-yoke worksheet.
Which size to print
- 24 x 36 in or A2: a main wall or team board, read from a few metres away.
- 18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
- Letter or A4: a clipboard, binder or handout, on any office printer.
Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.
Sources and notes
- Methods and functions as described by Shigeo Shingo, Zero Quality Control: Source Inspection and the Poka-yoke System (Productivity Press, 1986).
Templates, decks and guides to go with it
- Poka-yoke worksheetEach step's possible errors, prevention or detection, the method, a device idea and a verified box.
- PFMEA template (process FMEA)Failure modes, effects and causes rated for severity, occurrence and detection, with RPN before and after action.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Topic: Quality managementEvery guide we have on the subject, sorted.
A poster reminds. A routine makes it stick.
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