How to Check for Errors and Poka Yoke Approach

There are several approaches to checking for errors. In this article, I’ll discuss three common ways to check for process errors: Successive Check, Self Check, and Poka-Yoke (mistake proof).

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Below is a table that describes the three common strategies for checking errors and I also describe the positive and negative or each approach.

Of course, the approach of Lean Manufacturing is to employ Poka-Yoke wherever possible, as it is the most low cost and low effort approach to achieving zero defects. But, as in some things, it depends on your operation.

Successive Checks	Self Check	Mistake Proof (Poka-Yoke)
Associates check workof previous associate	Associates check own work beforepassing to the next associate	Automatic check and prevention of defect
Plus: Generally effective in catching defects	Plus: Instant correction possible and more palatable than supervisor check or peer check	Plus: 100% inspection usually with no extra time expense with the benefit of instant correction
Corrective action can only occur after defect is made	Associate may compromise quality or forget to perform self-check	None