1. “Those who are not dissatisfied will never make any progress
“Those who are not dissatisfied will never make any progress.” - Shingo
(1909 – 1990)

2. Dr. Shigeo Shingo Industrial engineer
Born January 8, 1909 in Saga City, Japan
In 1955 he took charge of industrial engineering and factory improvement training at the Toyota Motor Company
He was a leading proponent of statistical process control in the 1950s, but became frustrated with the statistical approach as he realized that it would never reduce product defects to zero
Died November 14, 1990 at the age of 81

3. Zero Quality Control (ZQC)
An approach to quality management that relies heavily on the use of Poka Yoke devices
Successive checks
Self-checks
Each method relies on 100% inspection whereas traditional SPC rely on random checks

4. Poka Yoke Japanese for mistake-proofing
Poka - inadvertent mistake
Yoke – prevent
Developed in the 1960s
Either prevents a mistake from being made or makes the mistake obvious at a glance

5. “The cause of defects lie in worker errors, and defects are a result of neglecting those errors – mistakes will not turn into defects if worker errors are discovered and eliminated beforehand” - Shingo
What would Dr. Deming have to say about that?

6. Three types of inspection
Judgment inspection
Informative inspection
Source inspection
Often Poka Yoke devices ensure the proper operating conditions exist prior to actual production

7. PokaYoke Device Categories
Prevention device - make errors impossible
Detection device - Make errors visible to the operator  

8. Characteristics of Good Poka Yoke Devices
they are simple and cheap
they are part of the process
they are placed close to where the mistakes occur
John Grout’s Poka Yoke Site