Defects = 0 is absolutely possible.
Management is often so focused on finding solutions that it fails to define the problems.
—Watts S. Humphrey
Poka yoke, a Japanese term that means mistake-proofing or fail-safing, recognizes that human errors are unavoidable but do not necessarily have to result in defects. It employs a set of proactive measures, particularly a 100% inspection at the source, to detect process errors before they cause defects. The emphasis is on prevention and quality measures at the source. This includes stopping the process upon detection of process errors that may cause defects downstream. The process is restarted ...