Poka-Yoke

Poka-Yoke or fool proofing involves devices which are often small jigs or other simple devices that are set up to avoid or detect errors.

A processed part cannot continue on the conveyor unless a specific sensor, which surveys some operation, has been activated.

A jig system to hold odd shaped parts.

A pin system which makes reverse tool setting impossible.

Poka-Yokes are often developed in the Kaizen context; a problem arises, an analysis is carried out to find out causes, and Poka-Yoke is used to ensure that the problem does not recur.