Achieving Zero Defects in The Production Line Through the Use of Poka-Yoke Techniques

Abstract

In an increasingly competitive industrial environment, organizations must consistently deliver defect-free products while maintaining cost efficiency. The evolution of Total Quality Management (TQM) and Total Productive Maintenance (TPM) across manufacturing and service sectors has introduced structured methodologies aimed at continuous quality enhancement. Techniques such as Kaizen, Six Sigma, Just-in-Time (JIT), Poka-Yoke, and Flexible Manufacturing Systems (FMS) contribute significantly to establishing a sustainable quality-oriented culture. Manufacturing processes frequently involve repetitive and routine tasks that may lead to operator fatigue and reduced concentration, thereby increasing the probability of human error. Given the inherent limitations of human performance, preventive quality control mechanisms become essential. The Poka-Yoke approach, based on mistake-proofing principles, offers practical and cost-effective solutions to eliminate inadvertent errors at their source. Its systematic implementation not only reduces defects and rework but also alleviates cognitive burden on workers. Consequently, employees are able to redirect their skills and creativity toward more value-adding and innovative activities, enhancing overall organizational performance and long-term operational efficiency.