Mi alles, C is óbal; Hol , Raimond; Ma in-Ga cia, Juan A.; Canos-Da os, Lou des
A icle
Uni e sal design o wo kplaces h ough he use o Poka-
Yokes: Case s udy and implica ions
Jou nal o Indus ial Enginee ing and Managemen (JIEM)
P o ided in Coope a ion wi h:
The School o Indus ial, Ae ospace and Audio isual Enginee ing o Te assa (ESEIAAT), Uni e si a
Poli ècnica de Ca alunya (UPC)
Sugges ed Ci a ion: Mi alles, C is óbal; Hol , Raimond; Ma in-Ga cia, Juan A.; Canos-Da os, Lou des
(2011) : Uni e sal design o wo kplaces h ough he use o Poka-Yokes: Case s udy and implica ions,
Jou nal o Indus ial Enginee ing and Managemen (JIEM), ISSN 2013-0953, OmniaScience,
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Uni e sal design o wo kplaces h ough he use o Poka-
Yokes: Case s udy and implica ions
C is óbal Mi alles1, Raymond Hol 2, Juan A. Ma in-Ga cia1, Lou des Canos-Da os1
1ROGLE-Dep o. de O ganización de Emp esas. Uni e sidad Poli écnica de Valencia (SPAIN)
2School o Mechanical Enginee ing. Uni e si y o Leeds (UK)
[email p o ec ed]; [email p o ec ed]; jama [email protected] .es;
louc[email p o ec ed]p .es
Recei ed June 2010
Accep ed Sep embe 2011
Abs ac :
Pu pose:
Employmen plays an impo an pa in many people’s li es beyond
me ely p o iding income, since con inued pa icipa ion in wo k can ha e many
he apeu ic bene i s o wo ke s de ined as disabled. Howe e , disabled wo ke s
ace a ange o ba ie s o employmen , despi e legisla ion in ended o imp o e
wo kplace accessibili y emphasizing adap a ions o he wo kplace, which many
employe s o en ind di icul and expensi e.
The Poka-Yoke app oach was de eloped in he manu ac u ing indus y as a way o
imp o ing p oduc i i y by educing e o s using o en e y simple adap a ions.
This pape a gues ha , as Poka-Yokes a e designed o make li e easie and imp o e
he pe o mance o wo ke s wi hou impai men s, hey a e close o he philosophy
o Uni e sal Design han o Accessible Design, and o e an easy and inclusi e way
o making wo k mo e accessible o all kind o wo ke s.
Design/me hodology/app oach:
This pape p o ides a case s udy
demons a ing he use o he Poka-Yoke app oach in a shel e ed wo k cen e o
disabled; highligh ing how hey se ed o imp o e accessibili y o wo k by ul illing
Uni e sal Design p inciples.
Findings:
Ou esea ch allows us o demons a e he g ea po en ial o Poka-yokes
o gaining accessibili y o he wo kplace. The eal applica ion o his app oach,
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bo h in shel e ed wo k cen es and o dina y companies, can con ibu e o imp o e
he high unemploymen a es o disabled people.
Resea ch limi a ions/implica ions:
The p oposal is inno a i e and was applied
in one speci ic company. Thus, a ange o cus omized Poka-yokes would be
desi able o di e en indus ial sec o s.
P ac ical implica ions:
Manage s o shel e ed wo k cen es, and also o o dina y
companies, can ealize abou he g ea po en ial o Poka-Yokes as an easy means o
gaining lexibili y and accessibili y.
O iginali y/ alue:
The e a e e y ew pape s ela ing lean manu ac u ing ools
and disabili y. Ou app oach analyzes he bene i s o his app oach o he labou
in eg a ion o disabled people.
Keywo ds:
lean p oduc ion, high in ol emen wo k p ac ices, shel e ed wo k cen e s
1 In oduc ion
Wo k plays a cen al ole in he majo i y o adul li es a many socioeconomic
le els. I main ains income and con ibu es o indi idual iden i y and social s a us.
The e is eme ging e idence ha con inued pa icipa ion in a wo k ole has
he apeu ic bene i s. F om he poin o iew o employmen , he e m “disabled
pe son” e e s o hose people whose oppo uni ies o ob ain and main ain a
sui able job and o p og ess wi hin ha job a e ema kably lowe han he gene al
popula ion due o a men al o physical de iciency (Lopez Pino e al., 2005).
O e he las h ee decades, he legal amewo ks and egula ions o he disabled
ha e been signi ican ly modi ied. Many go e nmen s ha e implemen ed policies
aimed a p omo ing he igh o he disabled o in eg a e as ully as possible in o
socie y. In his sense, social and employmen in eg a ion o he disabled has
ecei ed special a en ion in mos in e na ional egula ions, e.g. he Uni e sal
Decla a ion o Human Righ s, he Cha e o he nine een eigh ies om
Rehabili a ion In e na ional, he P og am o Wo ldwide Ac ion om he UN in
1988, o he Eu opean Social Cha e in 1981.
In iew o he abo e, a ious a emp s a e being made o u he he in eg a ion o
hese ci izens in socie y. Se e al coun ies deal wi h his p oblem h ough di e en
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in eg a ion app oaches and he awa eness ega ding his issue goes beyond he
public and go e nmen al sphe es. Indeed, unde he concep o Co po a e Social
Responsibili y (CSR), an inc easing numbe o companies a e becoming conce ned
wi h his ma e (Ko le & Lee, 2005). Since 1990, Social Responsibili y has ound
inc easing in e es in he li e a u e. Al hough in ce ain o ums he e a e doub s as
o whe he his boom is jus a passing end, ce ain indica o s e eal ha we a e
acing a eal change o pa adigm in which companies a e seen as esponsible o
some hing mo e han me ely ob aining maximum p o i (Gu hey e al., 2006).
In his scena io, he employmen o disabled wo ke s is seen as a way o including
he in e es s o socie y in he company goals. In ac , wo k in he compe i i e
wo k o ce may be a signi ican sou ce o enhancing adap i e skills o people wi h
disabili ies and, hus, g ea ly adding o he success o communi y li ing and socio-
labou in eg a ion (S ephens e al., 2005). In his sense, he second global epo
2007 abou Disc imina ion p esen ed as pa o he In e na ional Labou
O ganiza ion Decla a ion ela i e o he undamen al wo kplace p inciples and
igh s (ILO 2007), sugges s ha go e nmen s and companies adop non legisla i e
egula ions (no as social wellbeing policies, bu as a ques ion o human igh s and
social in eg a ion). Addi ionally i p oposes ha he ac i e policies, ac ions and
p og ams abou labou ma ke s should comba he disc imina ion o wo ke s wi h
disabili ies in h ee ways: (1) Via he o mula ion o policies and egula ions agains
disc imina ion in he wo kplace; (2) Via an inc ease in he oppo uni ies o people
liable o being disc imina ed o ind a job; (3) Via an imp o emen o he hi ing
p ocedu es in public and p i a e sec o s (Mi alles e al., 2010).
Bu despi e he g ea legisla i e e o s made by mul iple na ional and in e na ional
ins i u ions, o al social-employmen in eg a ion o people wi h disabili ies s ill
seems a away. This ac con i ms he pe cep ion ha he solu ion has o come no
only om legal egula ions ia go e nmen al measu es, bu also by o e coming he
p ejudices abou he capabili ies o he disabled, and by he genuine commi men
o companies o include in eg a ion p og ams in hei ope a ion s a egies and
models. Fu he mo e, he inco po a ion o disabled people o many p oduc i e
ac i i ies gene a es added alue o a company, as well as socie y as a whole, which
is pa icula ly imely gi en he cu en pensions c isis and ageing popula ion.
1.1 Aim and s uc u e o he pape
Mi alles e al. (2010) analyzed he global bene i s o ce ain Ope a ions
Resea ch/Managemen Science ools ha , i applied co ec ly, ha e a posi i e
impac on accessibili y o wo k. Following his a gumen a ion, his pape aims o
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show he g ea po en ial o one o he ools p esen ed in Mi alles e al. (2010): he
Poka-Yokes. I will be demons a ed how his managemen ool, ini ially designed
o minimize e o s and maximize p o i , also helps o achie e social-employmen
in eg a ion in he mos e icien possible manne , hus allowing he inco po a ion o
CSR p ac ices in companies.
The s uc u e o he a icle is as ollows: in he nex sec ion, a li e a u e e iew
shows he di e ences be ween Uni e sal Design and Inclusi e/Accessible Design
and s a es he philosophy o he p oposed app oach. Then a e iew on he Poka-
Yokes and i s po en ial is discussed. Sec ion 3 shows a case s udy whe e his
app oach was implemen ed wi h success in i e di e en wo ks a ions, each one
applying di e en Poka-Yokes. Finally, Sec ion 4 discusses he esul s achie ed in
he case s udy and Sec ion 5 summa izes he gene al conclusions and he u he
esea ch p oposed.
2 Li e a u e e iew
This sec ion e iews li e a u e on he wo main hemes o he pape : Uni e sal
Design and he wo kplace; and Poka-Yokes which migh help o achie e his.
2.1 Uni e sal Design and he Wo kplace
In many coun ies, a ange o legisla ion o imp o e employmen among he
disabled has been enac ed, such as he Ame icans wi h Disabili ies Ac (ADA) o
he Disabili y Disc imina ion Ac (DDA) in he UK. Bell and Hei muelle (2009)
a gue ha , a om imp o ing employmen a es among he disabled, bo h he
ADA and DDA may ha e wo sened i , due o he inc eased cos bu den placed on
employe s. The iew e lec ed in his legisla ion is one ha Sai o (2006) de ines as
Accessible Design, o special adap a ions o accommoda e wo ke s wi h disabili ies
so ha ba ie s o access a e elimina ed. While in p inciple his a laudable aim,
many companies, e en wi h he ins i u ional help hey may ecei e, canno a o d
i , pa icula ly gi en he highe absen eeism o disabled wo ke s due o heal h
p oblems, which can lea e expensi e adap ed wo kplaces s anding emp y (Mi alles
e al., 2007). Special adap a ions can also be a sou ce o esen men among non-
disabled colleagues (Cle eland e al., 1997); educe Quali y o Li e by calling
a en ion o he o he ness o a disabled wo ke (Lemai e & Mallik, 2008); and
companies o en pass on he cos o adap a ion o disabled wo ke s in he o m o
lowe wages (Jones & La eille, 2010).

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Sai o (2006) highligh s Uni e sal, o Inclusi e, Design as an al e na i e o he
Accessible Design philosophy embedded in cu en legisla ion. Uni e sal Design
seeks o a oid he need o special adap a ions by designing p oduc s and
en i onmen s ha can be used by he la ges p opo ion o he popula ion possible.
This app oach emphasises capabili y a he han disabili y, a guing ha disabili y
and exclusion a ise om poo design, and ha design which equi es a low
capabili y h eshold bene i s e e yone, no jus he disabled (Cla kson e al, 2003).
In his sense Uni e sal Design is ocused on se en co e ene s (Cen e o
Uni e sal Design, 1997):
• Equi able use: The design is use ul and ma ke able o people wi h di e se
abili ies.
• Flexibili y in use: The design accommoda es a wide ange o indi idual
p e e ences and abili ies.
• Simple and in ui i e use: Use o he design is easy o unde s and,
ega dless o he use ’s expe ience, knowledge, language skills, o cu en
concen a ion le el.
• Pe cep ible in o ma ion: The design communica es necessa y in o ma ion
e ec i ely o he use , ega dless o ambien condi ions o he use ’s
senso y abili ies.
• Tole ance o e o : The design minimizes haza ds and he ad e se
consequences o acciden al o unin ended ac ions.
• Low physical e o : The design can be used e icien ly and com o ably, and
wi h a minimum o a igue.
• Size and space o app oach and use: App op ia e size and space is
p o ided o app oach, each, manipula ion, and use, ega dless o he
use ’s body size, pos u e, o mobili y.
In p ac ice, i is ecognized ha he di e si y o he human ace makes uly
Uni e sal Design i ually impossible, and ha some deg ee o design exclusion is
ine i able, bu ha his should be kep o a minimum as a as possible (Cla kson
e al., 2003). This pape akes Uni e sal Design as i s co e philosophy. The
a gumen is no ha he e should be elimina ed bu ha , so a as possible,
adap a ions should be designed o bene i as many wo ke s as possible, ega dless
o disabili y. The e is a su p ising lack o li e a u e in his a ea: whe eas esea ch
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g oups such as he Helen Hamlyn cen e (Mye son e al., 2009) a e making in oads
in o inclusi e wo kplace design, hei ocus is on he design o he wo k
en i onmen and no on he design o he wo k i sel .
2.2 Poka-Yoke
The Poka-Yoke (a Japanese wo d ha means mis ake-p oo ing) echnique was i s
de eloped in 1961 by Shigeo Shingo. Poka-Yoke uses de ices on p ocess
equipmen o p e en he human o machine e o s ha esul in de ec s, o o
inexpensi ely inspec each i em p oduced o de e mine whe he i is accep able o
de ec i e. Poka-Yoke-designed manu ac u ing de ices a e one o he bases o
Shingo’s ze o quali y con ol concep s, which means ha he de ec a e in a
p oduc ion sys em is ze o. Poka-Yoke design can d ama ically dec ease he isk o
p oducing de ec i es p oduc s (Shingo, 1986). The Poka-Yoke philosophy also aims
o make wo k easie and p e en e o s caused by mono ony o o he p ocess-
ela ed causes.
In many p oduc i e en i onmen s, he e is a endency o equa e speed wi h
p oduc i i y. T adi ional enginee ing p ocesses a e designed o inc ease he
e iciency o an ope a ion by enabling people and machines o wo k as e , and
p ocesses a e usually complica ed o achie e g ea e speed; ye i is hese
complica ions which cause many o he e o s people and equipmen make,
esul ing in mo e de ec i e p oduc s.
By con as , he Poya-Yoke philosophy aims o inc ease p oduc i i y by simpli ying
p ocesses, making hem mo e e icien , educing he numbe o e o s ha need o
be co ec ed, and inc easing he o e all e iciency o he sys em. Poka-Yoke can be
used whe e e e o s can occu and can be applied o any ype o p ocesses and
helps wo ke s o be “ igh i s ime”, enhancing he quali y o he p oduc and he
o e all ou pu o he p ocess. Poka-Yoke suppo s e o s o elimina e was e caused
by: o e p oduc ion, in en o y, wai ing, anspo a ion, mo ion, o e p ocessing,
quali y de ec s, ep io i iza ion and also was e caused by people's skills. Mos
impo an ly, Poka-Yoke was de eloped wi h he aim o making wo k easie o
wo ke s wi hou disabili ies, and as such demons a e he alue o o en simple
adap a ions ailo ed o he job a hand.
I is o en assumed ha adap a ions o suppo he di e si y o si ua ions aced by
disabled wo ke s p esen a huge challenge o designe s. In ac , he ex a
in ellec ual e o needed o o e come disabili y o en esul s in a be e inal
design o bo h he disabled and non-disabled use s. In his pape , we a gue ha
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Poka-Yoke ep esen s a sui e o simple and ela i ely inexpensi e ways o
imp o ing access o wo k and he p oduc i i y and pe o mance o disabled and
non-disabled wo ke s, and a powe ul ool o implemen ing Uni e sal Design in he
wo kplace.
3 A ep esen a i e case s udy
This sec ion will desc ibe a case s udy whe e he po en ial o Poka-Yokes as a
means o wo k in eg a ion is demons a ed. The case s udy was de eloped in a
Shel e ed Wo k Cen e o he Disabled (hence o h SWD) close o he ci y o
Valencia (Spain) ha assembles di e en kinds o p oduc s. SWD a e a model o
socio-labou in eg a ion ha ies o mo e away om he adi ional s e eo ype
ha conside s disabled people as unable o de elop con inuous p o essional wo k.
Like any o he p i a e i m, a SWD compe es in eal ma ke s and mus be lexible
and e icien enough; he only di e ence being ha hei s a mus ha e 70% o
wo ke s wi h some kind o disabili y.
The SWD in his case s udy assembles and packages elec ical/elec onic de ices
and me al/plas ic p oduc s, and aking on any oppo uni ies ha become a ailable
in he ma ke . Al hough he company once employed mo e han 160 wo ke s, c isis
has o ced i o educe i s s a o 92 wo ke s, whe e 82 su e some kind o
disabili y; including some 40% wi h physical disabili ies, abou 55% o hem wi h
some men al disabili y, and he emaining 5% wi h some cogni i e impai men .
The company's main deals come om big in e na ional companies, who con ac
he SWD se ices o assembling ce ain p oduc s. The SWD usually ecei es aw
ma e ial and componen s om i s supplie , and e u ns he assembled p oduc .
Ful illing he clien 's equi emen s in bo h cos and quali y a e c i ical o ecei ing
u u e o de s. Only by a pe o ming well can he SWD ge new con ac s o new
p oduc s, and po en ially p o ide mo e jobs o he disabled.
In ac , his labou in eg a ion o mula has been e y success ul in dec easing he
o me e y high unemploymen a es o he Spanish Disabled. Despi e his, i is in
con en ional companies whe e he ue social–employmen in eg a ion o he
disabled should ake place: while SWDs e ec i ely p o ide e y necessa y wo k o
hese people, hey do no con ibu e so much o socie al no maliza ion (Mi alles e
al., 2010). I is impo an o ecognise ha his case s udy was de eloped in a
SWD because i p o ided access o a di e se wo k o ce o he pu pose o ou
expe imen a ion: ou long e m goal is o demons a e he po en ial o Poka-Yokes
o labou in eg a ion in o dina y companies.
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3.1 Ini ial si ua ion
Ini ially, he SWD used indi idual wo kplaces, designed wi hou any pa icula
conside a ion o disabili ies, so ha only a ew employees could comple e he
en i e assembly p ocess o mos o he p oduc s e icien ly. Mos wo ke s we e
e icien in some s eps o he assembly p ocess, bu had di icul ies wi h one o
mo e ope a ions, which made hei quali y yield and hei e iciency low. Fo
wo ke s wi h men al disabili ies i was e en mo e di icul , since mos o he
assembly p ocesses also included jobs ha equi ed high concen a ion and/o
capabili ies ha hey lacked.
Consequen ly, he SWD could only assign a subse o asks o each indi idual
acco ding o his/he limi a ions, esul ing in a low lexibili y o he wo k o ce whe e
he SWD was no able o adap o demand luc ua ions o new equi emen s om
clien s. In many cases, he SWD was unable o capi alise on inc eased demand o
a clien 's p oduc , due o he lack o lexibili y in i s wo k o ce.
3.2 Focus o he esea ch
In o de o es he alidi y o ou p oposal, he SWD's u ni u e assembly &
packaging sec ion, wi h a s a o wen y wo ke s, was analyzed. The capabili ies
and limi a ions o e e y wo ke we e s udied using bimanual analysis and lea ning
cu es (Smun and Wa s, 2003) o e alua e hei lexibili y and loca e possible
incompa ibili ies wi h he equi ed assembly asks a each wo ks a ion. The i e
wo ks a ions wi h mos incompa ibili ies we e selec ed o use as a pilo s udy.
Twel e o he wen y wo ke s had di icul y wi h he asks a one o se e al o he
i e wo ks a ions.
N .
Kind o disabili y
WS1
WS2
WS3
WS4
WS5
1
Men al
2 Men al
3 Men al
4
Men al
5 Men al
6
Men al
7 Men al
8 Men al
9
Men al
10 Men al/Physical
11 Physical
12
Physical
Table 1. Ini ial si ua ion o he i e wo ks a ions analyzed
Focusing on hese wel e wo ke s we go he ini ial da a in Table 1, whe e he
shaded cells ep esen he ac ual possible wo k assignmen s, and he non-shaded
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in es men in he wo k o ce, wi h imp o ed e iciency helping o co e he cos s o
implemen a ion. In ac , in his case s udy he o al implan a ion cos was
ex emely low compa ed o he high imp o emen , bo h in p oduc i i y and
lexibili y, o he whole u ni u e assembly & packaging sec ion.
To conclude i has o be no ed ha Poka-Yoke me hod was o iginally de eloped o
use in a manu ac u ing en i onmen , and ha is he con ex in which i has been
applied he e. Howe e , he Poka-Yoke app oach has ound implemen a ion in a
ange o en i onmen s, and i s po en ial o implemen ing Uni e sal Design
p inciples in o he ypes o wo k should be conside ed.
5 Conclusions and u he esea ch
This pape has illus a ed ha Poka-Yokes a e a po en ial ool o implemen ing
Uni e sal Design in he wo kplace, he co e bene i being ha - by inc easing he
ease o a ask - hey o e bene i s o all wo ke s, no jus hose wi h disabili ies. I
is impo an o ecognise ha his app oach does ha e limi a ions: as Table 2
illus a es, while access was imp o ed, he Poka-Yokes in oduced could no make
all asks accessible o e e y wo ke , emphasising Cla kson e al. (2003) poin ha
o al inclusion is di icul and minimising exclusion is a mo e ealis ic aim. Ha ing
es ablished he po en ial o Poka-Yokes as a ool o imp o ing wo kplace inclusion,
he key challenge is in de eloping ways o making his app oach easy o implemen
wi hou he need o specialis expe ise.
Fu he esea ch will be concen a ed on wo a eas: on he one hand, being able o
es ima e how a gi en Poka-Yoke will impac inclusion a es (one clea op ion is o
adap he Camb idge Uni e si y’s Exclusion Calcula o (Cla kson e al., 2003)). On
he o he hand, o design a p ac ical me hodology ou lining he s eps a company
should ake o de elop and deploy app op ia e Poka-Yoke in he wo kplaces.
Acknowledgmen s
The au ho s would like o acknowledge he unding o he Resea ch Suppo
P og am PAID-00-10 o Uni e si a Poli ècnica de València. They also would like o
acknowledge he SWD in ol ed in his esea ch.

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