ABSTRACT
The fi nal tool is poka-yoke, a methodology that focuses on preventing defects and improving quality. The goal of zero defects is achievable. The Zero Quality Control system approach of mistake-proofi ng (poka-yoke, in Japanese) prevents defects by monitoring process conditions and correcting errors at the source. It is human nature to make mistakes. In this approach, poka-yoke devices are used to perform 100% inspections and give feedback about each part or operation. Installing a poka-yoke device has a considerable effect on quality, but it can also give you a false impression that these devices alone will eliminate defects. However, if you combine poka-yoke systems with self-checks or successive checks, you can effectively obtain 100% inspections, prompt feedback, and action. To do that, it is essential for you to understand how to use poka-yoke systems, their functions, the types of systems, and various detection methods-all of which are covered in this chapter.
