Poka-Yoke
A Japanese term meaning mistake-proofing, referring to design techniques that prevent or detect human errors before they result in defects. Poka-yoke devices make it impossible to perform an operation incorrectly or immediately alert operators when an error occurs, improving quality at the source.
RELATED TERMS
Lean Manufacturing
A systematic approach to manufacturing derived from the Toyota Production System that focuses on eliminating waste while delivering value to customers. Lean identifies seven types of waste (overproduction, waiting, transport, overprocessing, inventory, motion, and defects) and uses tools like value stream mapping, 5S, and kanban to continuously improve processes.
Quality Management System
A formalized system that documents processes, procedures, and responsibilities for achieving quality objectives and meeting regulatory requirements. QMS provides a framework for continuous improvement, ensures consistent product quality, and helps organizations achieve certifications like ISO 9001.
First Pass Yield
The percentage of units that pass quality inspection without requiring rework, repair, or scrapping on the first attempt. First pass yield measures process capability and quality, with higher yields indicating more efficient operations and lower costs of poor quality.
Six Sigma
A data-driven methodology for eliminating defects and reducing process variation using statistical analysis and the DMAIC framework (Define, Measure, Analyze, Improve, Control). Six Sigma aims for processes that produce no more than 3.4 defects per million opportunities, representing near-perfect quality.