How to completely eliminate accidents caused by negligence! “The 10 principles and examples of the “Poka-yoke” method – keep this handy! (Share)

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Poka-yoke is a method to prevent incompetent people from making mistakes. Through measures such as design and improvement, even incompetent people can avoid making mistakes, thereby reducing human error and accidents. Why are the safety measures designed this way? These principles can help employees understand quickly and leave a deeper impression! The ten principles: 1. Root-cause elimination principle, 2. Safety principle, 3. Automation principle, 4. Conformity principle, 5. Sequencing principle, 6. Isolation principle, 7. Replication principle, 8. Hierarchy principle, 9. Warning principle, 10. Mitigation principle. Definitions and applications of the ten principles of error prevention: 1. Root-cause elimination principle: Eliminate the causes that lead to errors at their source, so that errors never occur. Mistake prevention is generally achieved through asymmetric shapes, tool improvements, elimination, and other methods. As shown in the improvement of flange pin positioning below, reverse installation is avoided. 2. Insurance principle: The insurance principle states that two or more actions must be carried out together or in sequence in order to complete a task. Typically, errors are prevented through actions such as coordination, sequencing, and interaction. Example: To open a bank safe, both the customer’s key and the bank’s key must be inserted into the keyhole simultaneously in order to unlock it. 3. Automatic control principles: These principles make use of various optical, electrical, mechanical, kinematic, chemical, and other principles to prevent the execution or suppression of certain actions, thereby avoiding errors. Currently, these automatic switches are very common, and they represent a very simple form of “automation” application. Typically, error prevention is achieved through controls such as buoyancy, weight, time, and direction. Example: When the elevator is overloaded, the doors cannot close, it cannot move up or down, and an alarm bell sounds. 4. Matching principle: The matching principle involves using actions to verify whether things match each other, in order to prevent errors from occurring. Typically, error prevention is achieved through methods such as differences in shape, symbolic indications, quantity indicators, and sounds. Example: It is necessary to check whether the quantity matches before and after surgery to prevent any tools from remaining inside the body and being forgotten. 5. Sequence principle: The sequence principle involves avoiding reversing the order of tasks or processes; by arranging them in numerical order, errors can be reduced or prevented. Typically, error prevention is achieved through numbering, slashes, and similar methods. Example: Many documents are stored in filing cabinets; whenever they are taken out for viewing and then put back, they end up in the wrong place. This problem can be addressed by using slashes as markers. 6. Isolation principle: This principle involves using partitions to separate different areas, thereby protecting certain zones and preventing the occurrence of any dangerous or erroneous situations. The isolation principle is also known as the protection principle. Such as putting bad people in prison, separating defective items, etc. 7. Copying principle: For the same task that needs to be performed more than once, it is best to use the “copying” method, as this saves time and prevents errors. Commonly, methods such as tracing, recitation, copying, and repetition are used to prevent errors. Example: When welding parts, one repeats the following words: “One, inspect (the incoming materials); two, place (the parts); three, press (the fixture button); four, make the mark; five, release (the fixture); six, remove (the parts); seven, place (them in the storage area).” 8. Stratification principle: The stratification principle is used to distinguish between different tasks in order to prevent mistakes in performing them. Generally, the thickness of lines and different colors are used to represent different meanings in order to prevent errors. Example: Attach a “red” label to defective items, mark dangerous areas in “yellow”, and paint pedestrian paths in “green”. 9. Warning principle: In the event of any abnormal conditions, various “warning” signals can be displayed through sound, light, or other means, in order to prevent errors from occurring. Example: When the vehicle’s speed is too high, the warning light comes on. 10. Mitigation principle: This principle involves using various methods to reduce the damage caused by errors. Although it is not possible to completely prevent errors from occurring, their impact can be diminished. Example: Car seat belts, wearing a helmet when riding a motorcycle. Steps of the mistake-proofing method: Identify human errors; set goals and develop implementation plans. http://img.proxx.xmtbang.com/?url=http%3A%2F%2Fmmbiz.qpic.cn%2Fmmbiz_jpg%2Fia7n83nTvQKryOibrWYFNDibnR2mOt9MNiaB2jDcoibvFURlTK0HkL2qAYMEAaQCwkSrVkI15sfWcDY2UDT2c9hVFDw%2F640%3Fwx_fmt%3Djpeg. Investigate the causes of human errors. http://img.proxx.xmtbang.com/?url=http%3A%2F%2Fmmbiz.qpic.cn%2Fmmbiz_jpg%2Fia7n83nTvQKryOibrWYFNDibnR2mOt9MNiaB2jDcoibvFURlTK0HkL2qAYMEAaQCwkSrVkI15sfWcDY2UDT2c9hVFDw%2F640%3Fwx_fmt%3Djpeg. Propose improvement measures using mistake-proofing techniques; implement those measures. http://img.proxy.xmtbang.com/?url=http%3A%2F%2Fmmbiz.qpic.cn%2Fmmbiz_jpg%2Fia7n83nTvQKryOibrWYFNDibnR2mOt9MNiaB2jDcoibvFURlTK0HkL2qAYMEAaQCwkSrVkI15sfWcDY2UDT2c9hVFDw%2F640%3Fwx_fmt%3Djpeg. Verify the results of the activities. http://img.proxx.xmtbang.com/?url=http%3A%2F%2Fmmbiz.qpic.cn%2Fmmbiz_jpg%2Fia7n83nTvQKryOibrWYFNDibnR2mOt9MNiaB2jDcoibvFURlTK0HkL2qAYMEAaQCwkSrVkI15sfWcDY2UDT2c9hVFDw%2F640%3Fwx_fmt%3Djpeg. Standardize and institutionalize the processes