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Poka-yoke (pronounced poh-kay yoh-kay) is Japanese for avoiding errors. It is a concept first promoted in the early 1960s by Shigeo Shingo(1) and later popularized by his 1986 book Zero Quality Control: Source Inspection and the Poka-Yoke System. Poka-yokes are inexpensive, simple methods built into processes that prevent defects by eliminating errors or alerting us when errors are made. The key trait of poka-yokes is that they make it impossible for the error to occur in the first place. For example, electric outlets and plugs are designed so that it’s impossible to insert them together in the wrong way. Though poka-yokes may appear to be most applicable to manufacturing, they’re used in all sorts of processes, products, and services.
# Automatic shut-off mechanisms for irons and portable heaters
# Car lights that automatically turn off the ignition is switched off
# Sink faucets with sensors that automatically turn the water on and off
# Automatic garage doors with sensors that stop the door from closing when they encounter an obstruction
# Color-coded file folders
# Electronic forms that validate city names to postal codes
# User accounts that aren’t activated until a confirmation email is responded to
# In-room self-checkout at hotels
# Fast-busy when an analog telephone is left off the hook

Most of us think of quality tools only as a way of enhancing the customer experience through the elimination of defects. But if we creatively applying the poka-yoke technique, we can not only make inexpensive improvements to our products and processes by preventing errors, we can add value by making them friendlier for the consumer to use. handiweb.