Title: Quality improvement through Poka-Yoke: from engineering design to information system design

Authors: Abraham Zhang

Addresses: Department of Management Systems, Waikato Management School, University of Waikato, Hamilton 3240, New Zealand

Abstract: Toyota production system (TPS) has extensive use of Poka-Yoke (mistake-proofing) devices. Poka-Yoke is also an essential process component of Motorola's Six Sigma strategy. However, Poka-Yoke has been largely ignored in academia. This paper advances the Poka-Yoke theory by formalising information system design (ISD) as a new way of design for Poka-Yoke through multiple case studies. Traditional engineering design Poka-Yoke has proven to be very effective to build quality into production processes. However, its application in non-production processes is very limited due to its reliance on physical features for error detection. In contrast, ISD Poka-Yoke is applicable for both manufacturing and service processes. Integrating wireless devices, ISD Poka-Yoke can even mistake-proof logistics processes which are often mobile in nature. Based on case study results, this paper presents a theoretical framework to unify developments in the design for Poka-Yoke. Practical guidance is also provided for Poka-Yoke implementation.

Keywords: lean thinking; TPS; Toyota production system; six sigma; quality management; poka-yoke; mistake proofing; information system design; information systems.

DOI: 10.1504/IJSSCA.2014.064260

International Journal of Six Sigma and Competitive Advantage, 2014 Vol.8 No.2, pp.147 - 159

Received: 18 Nov 2013
Accepted: 04 Jun 2014

Published online: 11 Aug 2014 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article