Quality Management (QMS) 13 items
IATF 16949 Error-Proofing / Poka-Yoke Verification Checklist
A checklist for designing, verifying, and maintaining error-proofing (poka-yoke) devices and challenging their effectiveness per IATF 16949 Clause 10.2.4.
IATF 16949:2016
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Identification & Design
- Are error-proofing methods determined from PFMEA and control plan risk analysis? *
- Is the device type appropriate (prevention preferred over detection)? *
- Are error-proofing devices documented in the control plan? *
- Device / station ID *
Challenge & Verification
- Are error-proofing devices tested with known-bad master parts at a defined frequency (e.g., each shift/setup)? *
- Are challenge test records retained? *
- Is a master sample set (challenge parts) controlled and calibrated where applicable?
Failure Response
- Is there a documented reaction plan for when an error-proofing device fails a challenge? *
- Is product produced since the last successful challenge quarantined and evaluated when a device fails? *
- Are device failures logged and analyzed for recurrence?
Maintenance & Effectiveness
- Are error-proofing devices included in preventive/predictive maintenance? *
- Is bypassing or defeating a device controlled and authorized only under defined conditions? *
- Is device effectiveness reviewed when nonconformities escape or PFMEA is updated?
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