Expanding the Meaning of Poka Yoke in Lean Manufacturing
PokaLean Manufacturing January 13, 2023We propose a new definition for poka yoke - a way to “error-proof” the manufacturing workforce to improve performance overall, instead of just fixing specific defects.
FAQs on Poka Yoke in Manufacturing
It’s a Japanese term meaning “mistake-proofing” or “error avoidance,” originally applied to processes and machines.
It’s used to prevent errors at the source through fixtures, sensors, digital systems, and connected worker tools that guide correct actions.
By shifting focus from machines to people, ensuring that worker knowledge is shared, standardized, and mistake-proofed across the workforce.
Industry 4.0 introduces digital tools, AI, and IoT for real-time error prevention, while Industry 5.0 emphasizes human-technology collaboration and sustainable manufacturing.
It raises overall performance, reduces errors across shifts, and ensures consistency, safety, and resilience—critical for both Industry 4.0 and 5.0 factories.