What Is Mistake Proofing (Poka-Yoke)
 

Mistake proofing (also called poka-yoke) is defined as an improvement technology that uses a device or procedure,  to prevent (or eliminate) defects or equipment malfunction during normal processing

Mistake-proofing devices enforce correct operations by eliminating choices that could lead to incorrect actions. These steps also could stop a process from creating errors or defects. These tools can prevent machine and product damage.
 

Mistake-proofing activities can be integrated with the lean tools of Quick-Changeover, 5S-visual-management, One-Piece-Flow, and Standard-Work. The possibilities for mistake-proofing are endless and typically involve very little investment in resources.
 

By applying mistake-proofing (poka-yoke) you ..:
 

*Promote individual responsibility for quality ownership.
 

*Conduct 100% inspection without the effort.
 

*Detect and eliminate defects as early in the process as possible.
 

*Provide immediate feedback, thus reducing the time for corrective action.
 

*Establish a system of successive checks for each operation.
 

*Provide self-check activities, which gives quicker feedback than successive checks.
 

*Ensure proper conditions exist prior to actual production, and prevents mistakes from occurring in the first place.
 

*Focus on elimination of causes for errors rather than just identification.
 

*Enhance customer satisfaction through the elimination of defects.
 

*Focus on waste reduction in defects and processing.
 

*Improve first-pass yield.
 

After reading this on mistake proofing, see here for more improvement tools.