The Toyota Production System places a lot of value on the avoidance of mistakes in an attempt to reduce the need for costly rework and repairs, as well as the expensive inspections that precede and follow the repair and rework. This process of “mistake proofing” is called “Poka Yoke” (ポカヨケ). In the video below, we show an example of this poka yoke principle that Toyota used in the past in their manufacturing process. It should be noted that today’s technology obviously allows for much more sophisticated solutions.
I really hate to fly longer than 2-3 hours, but in 2025 I found myself yet again on board of a plane, this time being imprisoned for almost 14 hours as it would fly from Amsterdam to Tokyo. This already long flight had become even longer due to the fact that certain airspace had to be avoided due to political factors. Be it as it may, with such an ocean of time at my disposal, I drafted a new offline course and I watched Joker Folie a Deux, not once but twice. I actually appreciated it too, contrary to the vast majority of people. In fact, I found it to be a masterpiece! I wanted to make the trip to Japan for years, but every time something had come up and I couldn’t get the factory access that I wanted. But this time was different and I managed to secure a good mix of factory tours and interviews with professionals and academics. The trip was worth the hassle. On the third day of the trip, I left an extremely hot Tokyo to travel to an even hotter Nagoya. I would have never im...
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