Error Proofing explained with examples.

Hi friends! Today we will discuss about Error proofing. It is also called Poka Yoke which is a Japanese word. It is also called Mistake Proofing. It is required in one of the clauses of IATF i.e. 10.2.4.

Error proofing is very popular in Manufacturing, some examples of it can be seen in daily life activities.

What is Error Proofing/ Mistake Proofing ?

 It is a process designed in such a way that if a person wants do mistake during the operation, this process/ system will not allow him/her to do mistake.

Why is  Poka Yoke used ?

• To minimize human error in operation.
• To increase product reliability
• Defect free product
• To prevent accidents, errors, or product malfunction.

Requirement of IATF

• Details of Error proofing methodology used shall be documented in the process (PFMEA)
• Test frequency of Error proofing of process/operation shall be documented in the control plan.
• Error proofing device failures shall have a reaction plan.

Let us understand with some examples.

1. Washing machine is a household machine used to wash our clothes. If automatic washing machine is running and we open its door, the washing machine automatically stops running.

2. Let us understand with some other examples.  We all are using mobile phone/ smart phone of different varieties today.  One thing is common in all mobile phones that if a valid sim is inserted in it, the phone starts operating.  Idea of putting a sim in all mobile phone is designed in such a way that if you want to put it in wrong way you cannot insert it. This is the beauty of mistake proofing/ Poka Yoke.  The system is designed in such way that even if a layman wants to put the sim inside the mobile, sim will have to be put in one and correct position only.

3. Elevator door – Elevator doors nowadays come with sensors to open its door when an object is obstructing the doorway to prevent people from getting injured. The door usually does not close until the obstruction is completely removed or moved.

4. Electrical socket – Electric sockets are designed so that only a certain type of cable can be plugged in to avoid short-circuits.