Mistake-proofing

What is error-proofing?

Error-proofing, also called mistake-proofing or poka-yoke, changes a process so an error is prevented or detected before it passes to the next step. This online checklist helps you record the proposed control, evidence, owner and follow-up.

Example: preventing a wrong-label mix-up

Fictional packing example: scan the order and label identifiers, compare them, and block release when they do not match. Test both a correct match and a deliberate mismatch using approved test materials. Record what happened, who owns the control and when it will be reviewed.

What does this tool do?

It helps plan and review controls. It does not connect to scanners, verify labels, stop equipment or enforce a production control. Those functions require a separately implemented and tested system. A reminder or checklist alone does not make a process error-proof.

Office example: a missing order identifier

Fictional example: a form reaches the next team without its order identifier. A reminder asks someone to remember the field; a validation rule in the order system can block incomplete submission. In this checklist, record the proposed rule and tests for a valid identifier, an empty field and spaces only. Record expected and actual results, an owner and a review date. ORDREL documents the test plan; the rule must be implemented separately.

Method reference: ASQ · Mistake Proofing