POKA-YOKE
Poka-yoke is a method for building quality into a manufacturing process
(versus trying to catch product defects after they are made through
inspections and the like.) True poka-yoke does not involve an extra step
or an extra process--- it is integrated into the process that actually
makes the product.
The term poka-yoke originated in Japan during the early 1960s. It is a
euphemism for another term: baka-yoke, which means “avoiding
stupidity.” Poka-yoke is best translated as “mistake-proofing.”
A
poka-yoke device often makes it impossible for a worker to continue a
process if a mistake is made. If this is not practical, the poka-yoke
may issue a warning.
For example, a sensor may verify that all the components of an assembly
have been included before a workpiece can be released to the next
process. If a component is missing, the sensor triggers a mechanism that
sounds an alarm and/or stops the line.