Quality Management (QMS) 11 items
Poka-Yoke (Error-Proofing) Verification Checklist
A checklist to verify the design, functionality, and routine challenge of poka-yoke (error-proofing) devices, ensuring detection or prevention controls remain effective during production per IATF 16949.
IATF 16949:2016ISO 9001:2015
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Device Design & Identification
- Is each error-proofing device identified and linked to a failure mode in the PFMEA and control plan? *
- Is the device type classified as prevention (mistake cannot occur) or detection (mistake is caught)? *
- Is the intended reaction on detection defined (stop, alarm, reject, contain)? *
Challenge / Verification Testing
- Are error-proofing devices challenged with known-bad master parts at a defined frequency (e.g., start of shift, changeover)? *
- Are both fail and pass conditions verified during the challenge? *
- Are challenge results recorded with operator, time, and result? *
- Are known-bad master/challenge parts controlled, identified, and calibrated/maintained? *
Failure Response & Records
- Is there a documented reaction plan when a device fails its challenge (containment of product since last good check)? *
- Are backup/alternate controls defined when a device is bypassed or under maintenance? *
- Is device maintenance and calibration included in the preventive maintenance program? *
- List devices verified and note any failed challenges and containment actions
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