When your organization is about to create a new product or process, you have the opportunity to establish flow in the most efficient way, right off the bat. The consistent use of pokayoke at the beginning of this new process will help you to avoid waste by using methods like quality tests and checklists to make sure there are no mistakes.

Imagine that you have been making a confectionery product that is produced on a manufacturing line. Because the product is rather sticky and sweet, it can jam up the machinery in a few key places. Therefore, maintenance employees must always be nearby to walk behind the machinery line and climb up on stepstools at least a few times each day to clear out the sticky mess and service the line.