Six Sigma DMAIC Process - Control Phase - Risk Assessment and Mistake proofing - Poka Yoke
Assess risks in the “should-be” process to make the solution more robust and preserve the gains over time. Evaluate potential failure modes and their effects, then prevent or reduce the identified risks. Two key techniques are:- Failure Modes and Effects Analysis
- Mistake Proofing (or Poka Yoke)
Mistake proofing, or poka yoke, comes from the Japanese words poka (inadvertent error) and yokeru (to avoid). It helps interrupt the path from an input error (X) to an unwanted outcome (Y). Depending on the design, it prevents the specific error or detects it promptly so the process can respond.
The key mistake proofing techniques are:
- Shutdown – Shutdown or stop a process immediately on occurrence of a failure
- Control – Prevent the process from proceeding until the relevant conditions are correct or the identified error has been corrected
- Warning – Signal an error or a condition needing attention so that action can prevent a defect or stop it from progressing
- Contact method – Contact with the part in the process highlights the errors
- Fixed-value method – Errors are detected in the process through counting
- Motion-step method – Check that required process steps occur in the correct sequence; a missing or incorrect motion can reveal an error
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