Question

Describe the difference between control pokayoke, warning pokayoke, and setting pokayoke. Give an example where you might apply each in your work or daily experience (allow yourself freedom to be creative on this).

Answer 1

Poka-yoke means mistake proofing in Japanese language and it helps to avoid mistakes in the lean manufacturing process. Control Poka-yoke and Warning Poka-yoke are regulatory poka-yokes. Control poka-yoke controls the process to prevent mistakes while a warning poka-yoke give warning about abnormalities or mistakes. A setting poka-yoke checks for proper settings in a process. A control poka-yoke shuts down the system when there is abnormality found and prevent other units getting affected. A warning poka-yoke only signals on abnormalities. Setting pokayoke are used in cases where positioning is important.

We use control pokayoke through security system in our work place. They act to control any chances of violence by checking all the members entering the premises and if they suspect anyone with dangerous weapons or wrong intentions, prevent them from entering the workplace. Thus protects all other employees from chances of violence.

An example for warning pokayoke is smoke detector placed in all the floors in our workplace. If there is fire, the smoke detector gives a warning alarm and the employees evacuate the place to escape from fire.

An example for setting pokayoke includes the process followed to enter highly confidential areas in our workplace which needs to follow a series of steps including permission from supervisor, providing access to the access card used by the employee and the security check before entering the premises. All these steps needs to be follower in the correct sequence, else the employee cannot get in and thus prohibits any chances of intruders..