This is the fourth in a series of columns that are discussing lean manufacturing and the use of lean methodologies by graphic communications companies.  My first column described the growing popularity of lean and reviewed the results of a recent survey conducted by PIA/GATF and Point Balance regarding the use of lean in the printing industry.  The second column discussed the primary business objectives and fundamental principles of lean.  Last month’s column discussed six tools and techniques that are used by most lean organizations to improve productivity and profitability—5 Whys, 5S, Autonomation/Jidoka, Cellular Manufacturing/Work Cells, Heijunka/Production Leveling, and Kanban.  This column will describe six more tools and techniques that play a central role in most lean implementations.

· Poka Yoke/Mistake Proofing—Poka Yoke is a methodology for preventing errors or

defects by putting limits on how a operation can be performed.  These limits essentially force an operation to be performed correctly, at least in some respects.  An example of Poka Yoke would be a “stop” on a drill press that prevents the operator from drilling too deeply, or a jig that will only hold materials if they are placed in the correct orientation.  The obvious objective of Poka Yoke is to prevent the production of defective products and thus avoid waste.