Poka-yoke payback calculator
Is an error-proofing fixture worth it? Enter how often the mistake happens, what it costs and what the fixture would cost, and see the payback period and first-year return.
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How the calculation works
Weekly savings = mistakes per week × cost per mistake × share prevented, plus inspection hours no longer needed × labour rate. Payback is the fixture cost divided by weekly savings. First-year ROI compares a year of savings with the fixture cost.
It's deliberately conservative: it ignores customer goodwill, less firefighting and the training time saved when the process can only be done one way.
Getting the inputs right
- How often: use your defect log or NCRs for the last 3 months, divided by 13.
- Cost each time: use the escape cost if the mistake reaches customers; it's usually far higher than rework.
- Share prevented: a physical fixture that makes the wrong way impossible is close to 100%; a warning light is lower.
- Fixture cost: simple 3D-printed nests and pins cost far less than sensor or vision systems. See how poka-yoke fixtures are designed and digital poka-yoke options.
Not sure what a defect costs you overall? Start with the cost of poor quality calculator.
Common questions
What is a good payback period for a poka-yoke?
Many simple error-proofing devices pay back in weeks. Under three months is usually an easy decision; under a year is still worthwhile for most manufacturers.
How much does a poka-yoke fixture cost?
It ranges widely: a 3D-printed locating nest or pin can be inexpensive, while sensor, interlock or vision systems cost more. The mechanism, materials and integration drive the price.
Should I count inspection time saved?
Only if you would actually reduce inspection once the error is prevented. If you'd keep inspecting, set it to 0.