National Aviation University, Ukraine

Poke Joke – Lean management method

Poke Joke is a Japanese term that stands for the Lean Management Methodology, the aim of which is preventing and avoiding intended as unintentional and accidental errors. The approach to this method is the theory that nobody can completely avoid unintentional defects and lapses. Poke Joke traditionally avoids most errors by technical means. A good example of such technical means is using different colors and shapes, sequential assembly plan.

The base of Poke Joke theory is the recognition that all people make mistakes, but these mistakes must be avoided and do not affect product quality. A very important task of the system is Poke Joke understanding of errors and their cause. There are various errors and incorrect actions that are made by people. Poke Joke system considers at least on the following 10 errors:

Illustration 1: 10 head errors

According to the Poke Joke theory to find an effective solution of the problem is important to use proper procedures. To avoid mistakes in the future process is necessary to learn the processes in the past and improve the processes used in the presence. The procedures for Poke Joke differ according to the time of problem identification.

Illustration 2: Poke Joke problem identification

For the error oriented Poke Joke system the error is known. The error is performed either on the final product or on any of the subsequent process steps. For the process-oriented Poke Joke possible errors are not known. The goal of the process-oriented Poke Joke is to find possible errors or human errors in existing products / processes and to prevent them. With this procedure, the individual process steps are observed and screened with the Poke Joke error list. The product-oriented Poke Joke system uses experiences and analyzes function-determining components regarding error protection.

In the structure of the Poke Joke system the Poke Joke system matrix plays a major role. Poke Joke system matrix consists of three columns. Each column holds 2 or 3 methods or functions. For solving a problem with the help of Poke Joke System, it is imperative to apply a method or function and find a horizontal path through the Poke Joke system matrix.

Illustration 3: Poke Joke System Matrix

Testing method	Tripping funktion	Regulating funktion
Checking the source of an error	Contact methods	Intervention method
Feedback test (direkt)	Constant value methods	Warning method
Feedback test (indirekt)	Step sequence methods	Warning method

For solving a problem with the help of Poke Joke System, it is imperative to apply a method or function and find a horizontal path through the Poke Joke system matrix. Typically, the measures that prevent the mistake or the wrong action are known as hard Poke Joke means: shape, size, stoptape, switch of process checking, same material, etc. (marked green). The measures that discover the error and the point the mistake out are known as soft Poke Joke: colour, checklists, lights, hupen, hints, etc. (marked yellow).

To find a lean decision, the whole process of finding solutions is structured and systematized. This helps not only to bring proper procedure into an order, but also find the effective instruments. Solution development procedure contains the following steps:

1. Problem analysis process by committing

2. Ideas through brainstorming

3. Review of the solutions

4. Decision and implementation plan

The aim of Poke Joke is to prevent human errors that can affect the quality of a product. A lean Poke Joke solution is characterized by the following features:

· The solution requires low investment and is quickly and easily implemented.

· The solution influences the quality of a product impressively.

· The solution does not need the implementation of additional steps, is part of the process and focuses on one or more potential error-processes.

· The solution was found together with the affected machine operators. The worker is not controlled but is supported to work effective.

· The solution makes the final control unnecessary.