What are the three types of poka-yoke?

Contact method (physical shape/size prevents errors), Fixed-value method (ensures the correct number of movements/parts), and Motion-step method (ensures steps are performed in the correct sequence). All three can be identified and validated through video analysis.

How does video analysis help with poka-yoke design?

Video captures the actual failure modes — not just what goes wrong, but exactly how and why. Frame-by-frame analysis reveals the specific moment an error occurs, helping engineers design targeted prevention mechanisms.

Glossary

Poka-Yoke — Mistake-Proofing in Manufacturing

Poka-yoke (ポカヨケ) is a Japanese term meaning 'mistake-proofing' — designing processes, tools, or fixtures that prevent errors from occurring or immediately detect them when they do. Developed by Shigeo Shingo as part of the Toyota Production System, poka-yoke devices range from simple physical guides (a part that only fits one way) to sensor-based detection systems. The goal is zero defects through prevention, not inspection.

Get Your FREE Demo See the Workflow

How to Create

Video analysis with Yamazo Studio helps identify where poka-yoke is needed. Record operators performing tasks and analyze for error-prone steps — moments of hesitation, incorrect sequences, or quality checks that rely on human judgment. Once identified, design poka-yoke solutions (physical guides, sensors, checklists) and verify their effectiveness by recording and analyzing the improved process.

Example

Video analysis of a connector assembly operation revealed that operators occasionally installed a gasket upside-down — a defect caught only at final test. A simple asymmetric fixture (poka-yoke) was designed that only accepted the gasket in the correct orientation. Post-implementation video analysis confirmed zero orientation defects.