MISTAKE-PROOFING (POKA-YOKE) CHECKLIST

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--- PROCESS IDENTIFICATION & RISK ASSESSMENT ---
[ ] Briefly describe the manufacturing process being assessed.
[ ] What risk assessment methodologies were used (e.g., FMEA, Cause-and-Effect Diagram)? (FMEA, Cause-and-Effect Diagram (Fishbone), Checksheet, 5 Whys, Other (Specify))
[ ] Estimated frequency of the critical process (units per hour/day/week)
[ ] List the potential failure modes in this process.
[ ] Severity rating (1-10) for each identified failure mode (1=minor, 10=critical)
[ ] Occurrence rating (1-10) for each failure mode (1=rare, 10=frequent)
[ ] Detection rating (1-10) of current controls (1=certain detection, 10=undetectable)
[ ] Document the rationale for selecting this process for poka-yoke implementation (e.g., high RPN score, frequent customer complaints).
[ ] Which method was used to prioritize processes? (RPN, Frequency of Error, Impact Score, Other)

--- DESIGN & IMPLEMENTATION OF POKA-YOKES ---
[ ] Which type of poka-yoke is most appropriate for this process? (Contact/Touch, Shape, Size, Color/Visual, Orientation, Fail-Safe)
[ ] Detailed description of the designed poka-yoke.
[ ] Diagram or sketch of the proposed poka-yoke.
[ ] Estimated cost of implementing the poka-yoke (in USD).
[ ] Which parts/processes will this poka-yoke impact? (Component A, Component B, Assembly Stage 1, Assembly Stage 3, Packaging)
[ ] Part Number of the poka-yoke (if applicable).
[ ] Target implementation date for the poka-yoke.
[ ] Potential issues anticipated during implementation and mitigation strategies.

--- CONTROL & MONITORING OF POKA-YOKES ---
[ ] Error Rate Before Poka-Yoke Implementation
[ ] Error Rate After Poka-Yoke Implementation
[ ] Poka-Yoke Performance Rating (e.g., Excellent, Good, Fair, Poor) (Excellent, Good, Fair, Poor)
[ ] Description of Observed Pokeyaoke Malfunctions or Issues (if any)
[ ] Last Pokeyaoke Maintenance/Inspection Date
[ ] Approximate Time of Error Occurrence (if applicable)
[ ] Potential Root Causes of Error/Malfunction (select all that apply) (Equipment Failure, Operator Error, Design Flaw, Maintenance Issue, Material Variation, Unclear Instructions)
[ ] Photos/Videos of Pokeyaoke and Observed Issues (if applicable)

--- OPERATOR TRAINING & AWARENESS ---
[ ] Explain the purpose of Poka-Yokes in the manufacturing process.
[ ] Which of the following best describes why we use Poka-Yokes? (To replace quality inspections., To prevent errors from occurring in the first place., To shift blame for errors., To increase production speed regardless of quality.)
[ ] Which of the following are potential benefits of effectively implemented Poka-Yokes? (Reduced defects, Increased production speed, Lower training costs, Improved employee morale, Reduced scrap and rework)
[ ] Describe how to respond if a poka-yoke activates or indicates an error.
[ ] What should you do if you identify a potential improvement to a poka-yoke? (Ignore it and continue with the current process., Implement the change immediately without notifying anyone., Report the suggestion to your supervisor or team leader., Implement the change after receiving approval from engineering.)
[ ] How many Poka-Yokes are you familiar with in your workstation?
[ ] Describe any concerns or questions you have about Poka-Yokes or their operation.

--- POKA-YOKE EFFECTIVENESS REVIEW & IMPROVEMENT ---
[ ] Current Error Rate (Prior to Pokayoke)
[ ] Current Error Rate (Post Pokayoke Implementation)
[ ] Overall Effectiveness Rating (1-5, 5=Excellent) (1, 2, 3, 4, 5)
[ ] Describe any observed anomalies or unexpected results from the Pokayoke.
[ ] What areas of the Pokayoke's performance require improvement? (Detection Accuracy, Ease of Use, Durability, Maintenance Requirements, Operator Acceptance, Other (Specify in Long Text))
[ ] Specific suggestions for improvement (if any).
[ ] Date of Last Review
[ ] Scheduled Date for Next Review
[ ] Reviewer Name
[ ] Reviewer Signature

--- DOCUMENTATION & STANDARDIZATION ---
[ ] Poka-Yoke Design Document Version Number
[ ] Detailed Description of Each Poka-Yoke Device/Method
[ ] Poka-Yoke Design Drawings/Schematics
[ ] Quantity of Each Poka-Yoke Device per Workstation
[ ] Applicable Processes Where Pokeyoke is implemented (Assembly, Machining, Welding, Inspection, Packaging)
[ ] Date of Last Poka-Yoke Documentation Review
[ ] Summary of changes implemented during last review
[ ] Current Status of Poka-Yoke Documentation (Draft, Approved, Under Review)
[ ] Document Controller Name

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