Quality Assurance

A Systematic Literature Review of Poka-Yoke and Novel Approach to Theoretical Aspects

“…Source inspection happens at the source [19] , before any action is taken, inspecting elements necessary for quality production [14]. Authors Hinckley and Barkan [3] argue that source inspection checks inputs such as man, machine, method, material and information in order to eliminate defects while processing.…”

“…Another cause of failures could be poor management support, training and process design [26]. However, blaming humans will not eliminate defects and problems in an environment [19].…”

“…According to Hinckley and Barkan [3], three sources of defects exist: variations as outof tolerance conditions; mistakes made by human or machine and complexity of product and process. Defects can be classified as isolated, which happen once, and those that happen frequently in a series [19]. If there is a complexity, the system has to be simplified.…”

“…Considering that even best workers are prone to mistakes, the term has been changed to mistake proofing [12]. PY has been used under different names such as error proofing [29], mistake proofing [39], idiot proofing, and fool proofing [19]. Some definitions by authors are summarized and described in Table 1.…”

“…Different methodologies and steps while implementing PY according to authors [19] and [50] could be summarized as follows: problem identification, workstation observation, identification of most frequent errors, identification of error sources, propose PY solution, evaluate solution, choose the best solution, design PY, implementation, testing, monitoring, maintenance and continuous improvement. Brainstorming, FMEA and Ishikawa diagram have been used in order to discover sources of defects or while choosing the appropriate PY solution for the problem.…”