In manufacturing, the best way to reduce errors is to design the system so that mistakes are hard to happen.
| # | Entity | Score |
|---|---|---|
| 1 | Poka-yoke | 61.8 |
| 2 | Sensors | 39.9 |
| 3 | Lean manufacturing | 19.6 |
| 4 | USB-C connectors | 16.8 |
| 5 | fixtures | 16.7 |
| 6 | the ability to make any USB plug go in correctly on the first try | 14.4 |
| 7 | Automation | 14.1 |
| 8 | Shigeo Shingo's work on poka-yoke | 11.5 |
| 9 | color coding | 11.3 |
| 10 | Asymmetrical parts | 10.7 |
#1Poka-yoke#2USB connectors
#1error-proofing#2poka-yoke#3USB-C connectors#4Car gear shifts#5Asymmetrical parts#6Software confirmation dialogs
#1Physical / Mechanical Constraints#2Process Controls & Automation#3Standardized Work & Visual Management#4Fail-Safe / Redundancy#5Error Detection & Immediate Feedback#6Design for Manufacturability#7Human-Factor Engineering#1Map the Process#1value-stream map#1process flow diagram#2Identify Failure Modes#2Failure Mode & Effects Analysis#2Design FMEA#2Process FMEA#3Apply the “4-T” Poka-Yoke Matrix+14 more
#1Poka-Yoke (Mistake-Proofing)#2Shigeo Shingo#3Error-Proofing#4Design for Manufacturability (DFM)#5Standardization#6Automation#7Connector Shapes#8Jigs#9Fixtures#10Color-Coding#11Automatic Shut-off Systems#12sensors
#1Poka-Yoke#2Shigeo Shingo#3Toyota#4Asymmetric connectors#5USB plugs#6color-coded slots#7Fueling aircraft#8Vending machines#9Sensors#10Surgery kits#11Checklists#12RFID tags#13FMEA—Failure Mode and Effects Analysis#14Contact sensors#15guides+3 more
#1error-proofing#2poka‑yoke#3keyed connectors#4fixtures/jigs#5sensors/interlocks#6software/HMI checks
#1error-proofing#2poka-yoke#3Standardization#4Standardized operating procedures (SOPs)#5Visual Controls#6diagrams#7color coding#8labels#9Automation#10automated systems#11equipment#12Error Detection#13sensors#14Feedback Loops#15Continuous Improvement (Kaizen)
#1Poka-Yoke#2USB-C cable#3traditional USB-A plug#4polarized plug#5sensor#6assembly line#7conveyor belt#8car#9dashboard light#10Checklists & Sequencing#11Software#12data fields#13sensors#14Contact Sensors#15Limit switches+1 more