Not Exactly Poka-Yoke and Chaku-Chaku

“Japanese automobile manufacturing methods are adopted by American competitors. Watch the concept of poka-yoke, meaning “correct” and chaku-chaku, meaning “one worker, several tasks” in the manufacture of rear view mirrors.”


Michel Baudin‘s comments:

An interesting video, but “Poka-Yoke” and “Chaku-Chaku” don’t mean what the narration says they do. And they are not “Japanese” methods but methods invented by specific individuals in specific companies that happened to be in Japan. Likewise, the assembly line is not an “American” method but a method invented by P.E. Martin, Charles Sorensen and others at Ford.

“Poka-Yoke” doesn’t just mean “correct.” More specifically, a Poka-Yoke is a device integrated in the production process to prevent human error or detect it immediately without adding any labor. Checking bar codes on parts, as shown in a video, doesn’t qualify as a Poka-Yoke because it adds labor, and error prevention devices that add labor are ineffective because they are by-passed under pressure.

The video shows an operator attending to a sequence of tasks and calls it “Chaku-Chaku.” There is, however, ,more to Chaku-Chaku than this, such as automatic processing at each station, with automatic unloading and chutes between stations, so that the work of the operator is focused on checking the part after an operation and loading it into the next.

See on Scoop.itlean manufacturing

3 comments on “Not Exactly Poka-Yoke and Chaku-Chaku

  1. Michel, you can add all the ergonomic issues workers are facing, useless transportations and movements. Another fake lean factory with managers and workers feeling they are doing it right.
    Thank you for sharing.

    • I didn’t mean to bash this plant, which I have never visited. In particular, I don’t know how they used to work five or ten years ago, and I wouldn’t presume to pass judgement on the extent to which they improved it. All I reacted to was the video’s claim to explain Poka-Yoke and Chaku-Chaku

  2. Pingback: What Poka-Yokes Are And Are Not, And How To Sustain Them | Michel Baudin's Blog

Leave a Reply

Your email address will not be published. Required fields are marked *