Quality improvement through Poka-Yoke: from engineering design to information system design Online publication date: Mon, 11-Aug-2014
by Abraham Zhang
International Journal of Six Sigma and Competitive Advantage (IJSSCA), Vol. 8, No. 2, 2014
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.
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