How to Implement Poke Yoke in 5 Easy Steps to Prevent Human Errors.

how to implement poke yoke in 5 steps


In this article, you will learn how to implement Poke Yoke in 5 simple steps.

Poka-yoke is intended to prevent human mistakes, or reduce them to acceptable levels.

Steps to Implement Poka Yoke in your Product or Operations.

Step 1. Identify the Most Common Type of Errors that You Want to Prevent.

List the most severe and frequent types of errors observed during the use of your product or during your manufacturing operations.

Then, put them in the priority order in which you want to prevent it.  Starting with the most critical and important and finish with the less relevant to your customers and company.

Also, identify all different modes of error detection that poka-yoke recognizes for your types of errors.

Step 2. Ensure that Correct Techniques are Selected to Prevent Human Error(s).

Make sure you have selected the appropriate procedures for those errors as early and anticipated as possible in your workflow.

Evaluate your operations, processes workflow and find out how to prevent the most common and critical errors, so that your operators, clients, and end-users are prepared to detect the situation or error before it occurs.

Some of the most common techniques are:

      • Color code.
      • Dimensional constraints and geometric form aids
      • Visual aids

Step 3. Implement a Visual Aid System to Prevent Human Errors.

You must learn from your previous errors. And of course, establish the instructions necessary to prevent the errors based on knowledge and experience from historical errors.  How to Implement Poke Yoke

Make sure you have enough data available in your systems to make statistical analyses and projections to measure the improvements obtained on each poke yoke implementation.

Step 4. Improve Continuously your Process

Use all information and knowledge obtained to find out the best manner to improve your process, products, and operations in terms of accuracy, precision, and reliability of error detection. How to Implement Poke Yoke

Step 5. Obtain Feedback from the End-users, Clients, and Operators Themselves

Find out the opinions and recommendations from the people who are getting the impact or benefits of your improvement to prevent human errors.   Obtain all the input and insight information as possible, and dialog with them on other what kind of errors they are observing.

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CIQA is a quality and regulatory consultant with 25 years of experience developing products and managing projects in the medical device supply chain, and pharmaceutical industries. Rest assured of the safety or being in the right hands.

Our Lean Manufacturing team could provide you a broad range of professional expertise implementing these techniques and tools.


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Quality procedures templates

Three (3) Options to Create Document Control Management DCM Procedures:

Bronze Option. You Can Create Your Own Quality Procedures, using a Template.

You can download samples of the Document Control Management DCM procedure templates in .pdf format. 

To see the complete list of the most popular quality procedures templates, click here.

In addition, you can request a quotation to buy online a full SOP template document in MS Word format that is completely editable, ready to fill, and adapt to your specific needs.

Silver Option. We Can Bring You Formal Training about How to Implement Poke Yoke.

This option is recommended if you want to learn more about how to build robust quality system procedures. One of our expert(s) can provide online step-by-step training to your team (unlimited assistance) on how to build reliable SOPs using our template(s). Also, you can improve your corporate quality procedures and policies by incorporating our template(s) and tools.  It includes a fully editable template from the Bronze option, plus training, exams, and a training certificate for each assistant.  Request a quote now.

Gold Option. We Can Create Customized Quality Procedures.

One of our expert(s) will create and prepare your customized SOPs with the inputs and specific information of your company. It includes a fully editable template from the Bronze option, plus online support in document creation, implementation, and training. Request a quote online.

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REFERENCES: How to Implement Poke Yoke.






Picture of Ramon Cayuela, MS, BS, Chemical Engineering

Ramon Cayuela, MS, BS, Chemical Engineering

CIQA President and CEO.
I've been working in validation engineering since 1992 with many multinational pharmaceutical companies. I love sharing my passion and knowledge with others. If you have any questions about anything (or just have general questions). I will be more than happy to assist you. You can count on the BEST customer service on CIQA. I go to great lengths to make sure my clients are 100% satisfied with their purchases and check emails/messages consistently throughout the day. You can rest assured that everything being sold here is as-described or your money back. I look forward to working with you!