What does “Error-Proofing” (Poka-Yoke) aim to achieve in a process?

"Error-Proofing," or Poka-Yoke, specifically aims to prevent errors from occurring in processes by implementing design mechanisms that make it difficult or impossible for mistakes to happen. The concept revolves around creating systems that either provide immediate feedback to the operator when an error is about to occur or physically prevent the process from continuing when conditions are not met.

For instance, in a manufacturing setting, Poka-Yoke could involve the use of fixtures that ensure parts can only be assembled in the correct orientation or sensors that alert operators if a key component is missing. This proactive approach not only preserves the quality of the final product but also enhances overall efficiency, as rework and defect rates are significantly reduced.

While error-proofing can indirectly influence costs, employee training, and production speed, its primary focus remains on embedding functional designs that inherently minimize the risk of errors in the first place. The effectiveness of such systems can lead to lower costs and improved performance, but these are byproducts of the primary goal of mistake-proofing processes.