Zero Quality Control: Source Inspection and the Poka-Yoke System

by Shigeo Shingo

A combination of source inspection and mistake-proofing devices is the only method to get you to zero defects. Shigeo Shingo shows you how this proven system for reducing errors turns out the highest quality products in the shortest period of time. Shingo provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement. He also discusses inspection systems, quality control circles, and the function of management with regard to inspection.

Genres: Business, Management

330 pages, Hardcover

First published April 1, 1986

Reviews

[Emily Yu · Rating 3 out of 5]

What can I say? This was better than expected. I had to read this for work and expected a dry narrative or instructive manual on how organizations could attain zero quality control. Adding to that, this was in the context of manufacturing. Quite frankly, I expected to fall asleep after page 2. To my surprise, I powered through this book in substantial increments (yes, that is, chapter by chapter). I liked how Shingo presented only a handful of concepts and drove them home through actual examples and good old repetition.

Shingo really goes after statistical quality control from the start of the book. This is due to his having been a believer of SQC himself. He offers a few straightforward and relatively convincing reasons why SQC doesn't get to zero defects the way poka-yoke and source inspections can (and do so at minimal cost and time). Also to his credit, he doesn't completely disown SQC; he acknowledges the usefulness of statistics, but believes he has the solution to achieving zero defects where SQC could not.

As for other gems to find in this book, there is a chapter where he makes a good clarifying argument around the role of inspections in the workplace. I appreciated it because it really brought the whole point of quality control around. Are inspections indicative of good quality? Or are they symptomatic of a defective process? He also has some interesting distinctions and models with regard to processes vs. operations as well as management functions as related to quality control. But I'll spare you a summary (which I could easily do here) of his points and encourage you to overlook the sad coloration of the book and give it a shot.

For pickier readers, be forewarned that the English version is very likely translated from Japanese. As a result, the writing and method of sharing the concepts may not appeal to a Westerner's reading sensibilities. My co-workers weren't too crazy about his writing style.

[Hadi Rachmad · Rating 5 out of 5]

the book is good, because topic of the book very important

[Mike Thelen · Rating 4 out of 5]

Shingo was a master. This book is a bit difficult to read if you aren't in Engineering, but it is still a masterpiece.

[Jimmacc · Rating 4 out of 5]

Excellent book. Very well documented, and a resource.