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POKA YOKE
Examples in the AEC Industry

Development of this web page was funded in part by the National Science Foundation under Grant No. 0116877. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the developers and do not necessarily reflect the views of the National Science Foundation.

Further development of this page is being funded by membership contributions to the PROJECT PRODUCTION SYSTEMS LABORATORY (P2SL), the Learning Lab for the Northern California Construction Industry.

Colored nail heads
The heads of these pneumatic nails have different colors to correspond to different lengths and diameters. This makes it easy to verify whether or not nails were installed according to a nailing schedule.

Source: Hawks, J. “Tool Review: Color-Coded Pneumatic Nails.” Fine Homebuilding Magazine reprinted on http://www.taunton.com/finehomebuilding/pages/h00090.asp visited 5/23/06.

Pop rivet

Getting the torque on bolts right is very tricky business for many companies. Huck fasteners mistake-proof this problem using a hybrid: half “pop-rivet,” half bolt. The tension on the bolt is created in a linear fashion and the “nut” is clamped in place and the excess bolt length is cut off. The only drawback is that removal involves cutting the bolt off and installing a new one after repairs.

Source: Example number 34 from http://www.mistakeproofing.com/Buy_Books/Example_set_5/example_set_5.html#huck visited 5/23/06.
Preformed sealant groove
Weathertightness is a top priority in roofing systems. Preformed sealant grooves and guides in system panels promote accurate sealant placement between panels.

Source: http://www.butlermfg.com/images/level3_pages/returnleglink-large.jpg visited 5/23/06.
Sink Clearance ADA requirements specify minimum clearances so that people in wheelchairs will have equal access to facilities. Minimum clearances may be jeopardized, however, because designers add aprons for aesthetic reasons to hide plumbing under sinks in restrooms.

The challenge, especially in settings such as this restroom, is that the floor slopes to allow for drainage (see drain). As a result, clearance under the sink varies from one sink location to another. Failure to meet ADA requirements leads to a significant amount of rework in the construction industry.

To guarantee access, a section of the apron is hinged so that a person can push it up to the height needed to gain access.

Source: Photo by Iris D. Tommelein, Oakland Airport.
Plumbing Pipe Building systems (e.g., plumbing, electrical, HVAC) have to penetrate through floor slabs. The dimensions of the required openings vary by system. Dimensional variation occurs when measuring the location of openings and when casting the concrete slab.

Here, standard-size block-outs were inserted and cast in the concrete slabs. To bridge the gap, clamps are used to support the pipe and transfer the load to the slab.

Source: Photo by Iris D. Tommelein, Infill Housing on
UC Berkeley campus.
  Anchor bolts must be spaced evenly and cast into concrete to protrude from the surface so that light poles can be mounted and plumbed. AJ Speedset™is an adjustable jig (from there 'AJ') that creates a simplified, time saving way to install ¾”, 1”, 1¼” or 1½” anchor bolts in concrete for area lighting. 

Source: http://www.rndproducts.com/ visited 4/30/07.

Last updated IDT 4/30/07