Poka-Yoke – Error prevention in logistics automation
Poka-Yoke (Japanese for "avoiding inadvertent errors") is a central principle from lean manufacturing. The goal is to design processes so that operator errors are technically impossible – or at least immediately detected and corrected. In the context of smart locker systems, this means: incorrect handovers must not occur in the first place.
1. Application in smart lockers
In automated handover and logistics processes, Poka-Yoke ensures that users can only perform the correct actions. TIKI SHARE smart lockers implement the principle technically: sensors, RFID identification and platform logic check every step before releasing the compartment.
2. Concrete examples from the BVG project
- Wrong depot: If a technician tries to remove a spare part at the wrong location, the system refuses release – the SAP assignment from the DESADV dispatch advice prevents incorrect removal.
- Time overrun: If a compartment is not emptied or filled after a defined time, the system automatically escalates and notifies logistics.
- Unreadable barcodes: Instead of error-prone optical capture, technicians identify themselves via RFID card – ambiguous scans are completely eliminated.
How the principle looks in practice is shown in the BVG case study with three automated depots.
Plan an error-proof process?
We show you how Poka-Yoke mechanisms can be integrated into your logistics or handover processes with TIKI SHARE.
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