Using Poka-Yoke to Error-proof Your Processes

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The Japanese term Poka-Yoke means integrating a mechanism into a process to prevent human errors from being made - such as mis-identifying parts that look alike, or packing the wrong part or quantity into a shipping container. 

Mistakes can be prevented by automating a manual task and eliminating the human touch point. Or they can be prevented by alerting the operator in real-time that an error is being made, requiring a correction before the operator can proceed further. 

SPEDE Poka-Yoke solutions can error-proof processes such as:

• Routing WIP through the correct sequence of operations
• Identifying parts /components at issue to WIP, pack/ re-pack
• Counting parts for pack count
• Packing dunnage layers
• Printing the correct container label 

SPEDE Poka-Yoke solutions can use:

• PLCs to control container labeling by supplying the part number, run data and piece count 
• PLCs to control part counts at start and end of run and to control partial packs 
• Vision sensors to identify / validate parts or components
• Vision to detect scrap; trigger defective parts to be diverted
• Vision or OCR to read a 2D serial number or text data for traceability
• Vision to control packing and labeling 
• Weigh scales to control piece counts / full pallet validation
• Weigh scales to trigger a container label when count or weight is correct
• Cameras at packing to ensure dunnage layer is packed correctly before the next layer can begin