Mistake Proofing (poka-yoke)

The Control phase of the DMAIC process utilizes a tool called mistake proofing. The Japanese term is known as poka-yoke. Mistake proofing creates a monitoring, gauging, and feedback system to instantly detect and control trends. Mistake proofing is applicable to any process; however, the term is mainly used in the manufacturing process. This key concept was widely used by Henry Ford in Model T production as early as 1908.

Mistake proofing systems prevent errors and defects from passing through the process. Front-line operators are empowered to stop a machine or entire production line if a problem arises. Mistake-proof devices, such as gauges or measurement tools, ensure that the defects are caught and corrected before defective products are produced.