Mistake Proofing Training | Poka Yoke

Mistake Proofing Training, Poka Yoke

Poka yoke, which translates into mistake proofing, is the use of a mechanism or device that helps avoid mistakes.

The purpose of the poka-yoke technique is to eliminate product defects by preventing them in the first place, correcting them or drawing attention to human errors as they occur. In manufacturing, this means not accepting, creating or allowing defects to move down the line.

Self-driving cars are a modern consumer-based example of poka-yoke. They operate by using multiple sensors and alerts like automatic braking and a variety of cameras to “see” everything around them in real time. Automatic braking systems are becoming a common feature in most new cars, helping prevent accidents due to human error.

For poka-yoke mistake proofing to work, it’s paramount to embrace an attitude of lean problem-solving. As long as organizations continue to think in terms of who is to blame, instead of how  the process failed — businesses will not be creative enough to generate the solutions they need.

Mistake proofing is intended to take quality control to the next level by checking for mistakes and defects before those defects can proceed to the next stage of production.  Preventing defects from proceeding from one stage of production to the next avoids wasted time and resources spent working on defective parts.

Organizations turn to mistake proofing for many reasons, such as when a process step has been identified where human error can cause mistakes or defects to occur, especially in processes that rely on the worker’s attention, skill, or experience.

Mistake proofing is also used in a service process, where the customer can make an error which affects the output, or at a hand-off step in a process, when output (or for service processes, the customer) is transferred to another worker.

When a minor error early in the process causes major problems later in the process, companies will often employ a mistake proofing strategy. Also when the consequences of an error are expensive or dangerous.

Although poka-yoke can be used in any business, it’s been especially prominent in the manufacturing sector where defective products can be very costly. Some customers will return a whole batch of parts if they find just one of them to be defective. And some products are manufactured for safety critical applications in motor vehicles, aerospace and oil exploration etc.

A failure in these areas can have very serious consequences and potentially cause loss of life.

Mistake Proofing Training Course by Tonex

Our Mistake proofing training course introduces participants to the fundamentals, process, techniques, and devices necessary to eliminate mistakes before they happen.The simplest, fastest, and most effective way to eliminate mistakes is to alter the pathways that lead us to make them. For instance, the fewer steps workers need to memorize to do their job the fewer mistakes they can make. Therefore, mistake-proofing solutions build many repetitive tasks into the process itself.

Once people’s minds are free and they are not under the stress of remembering tasks, they have the time and the chance of being creative and more efficient. Mistake proofing training course will help you develop such solutions based on your business. Students also will learn about four different approaches to change a process to eliminate mistakes:

• Prevention method
• Detection method
• Fail-safely method
• Work environment

Moreover, through our Mistake Proofing Training course, you will learn how to change the mindset of your organization. Change must start from the leaders and those who establish the process. Leaders must conceive the belief that mistakes are not welcome or acceptable in the organization. They are the ones who must establish a mistake-proofing mindset among the employees. The mistake proofing training course will help you implement such a system, get the decision makers on board, and educate your team to get comfortable with the process.

Audience

Mistake Proofing Training is a 2-day course designed for:

• Executers and decision makers of the organization
• Leaders
• Managers and supervisors
• Engineers
• Business process owner
• Process improvement managers and leaders
• System implementers and coordinators

Training Objectives

Upon the completion of mistake proofing training course, the attendees are able to:

• Understand the goal and importance of mistake proofing
• Identify the mistake-proofing solutions in the daily life
• Apply mistake proofing methods and techniques in their work to reach the zero defects process quality
• Recognize the input elements of each process
• Identify the source of mistakes
• Use practical approaches to cut off the non-quality cost
• Implement the mistake proofing Seven Criteria
• Use the Five Mistake-Proofing Imperatives
• Choose the best mistake-proofing devise by using the Ten Point Scoring Technique
• Recognize the forced control effect
• Identify some of the types of the shutdown effect sensors
• Apply sensory alert effects
• Find the root cause
• Apply proper mistake proofing solution in each root cause
• Evaluate and assess the applied solution in regards to its effectiveness, feasibility, and cost
• Avoid overriding the solution by building it in the process
• Check how much your solution is robust

Overview To Mistake-Proofing

• What is mistake proofing or poka yoka?
• How to find the source of mistakes
• How to set a mistake-proofing mindset among your organization
• Zero Quality Control (ZQC)

Introduction 

• Basic functions of poka yoke
• Poka yoke culture
• Positive and negative cultures

Daily Life Mistake-Proofing Solutions

• Find examples of mistake-proofing around you
• How to get ideas from them at work

Defects And Costs

• Importance of ZQC
• Costs of defects
  • Extra work
  • Scrap
  • Warranty costs
  • Inspection costs
• The 1-10-100 rule

Reasons Behind Mistakes

• You harvest what you planted
• Importance of identifying root causes of mistakes
• Common mistakes causing defects
• Common defect categories

Zero Defect Quality System (ZDQ)

• Definition and concept
• How ZDQ makes your work easier
• How to achieve ZDQ
• Components of ZDQ
  • Inspection
  • Audit checks
  • Immediate feedback
  • Poka yoke

Principals Of Mistake-Proofing

• Preventing mistakes
  • Elimination
  • Replacement
  • Facilitation
• Minimizing the effects of mistakes after they are made
  • Detection
  • Mitigation

Mistake-Proofing Process

• Process overview
  • Quality process
  • Team environment
  • Eliminate errors
  • Do it right the first time
  • Eliminate excuses
  • Implement improvement actions
• FEMA analysis
• Root Cause Analysis
• Develop and implement mistake-proofing solutions
• Control Plan

Root Cause Analysis Tools for Mistake-Proofing

• The 5-whys
• What is and what isn’t a problem
• Data collection and display
• Failure analysis
• Simulations
• Statistical analysis
• Check the root cause back

General Failure Modes

• Process failure
  • Omission
  • Excessive repetition
  • Wrong sequence
  • Early/late execution
• Selection failure
  • Incorrect identification
  • Incorrect calculation
• Perception failure
  • Overlooking
  • Misreading/Misunderstanding
  • Incorrect decision
  • Miscommunication
• Motion Failures
  • Incorrect transcription/entering
  • Incorrect route/orientation/positioning/setting
  • Unintentional touching/sticking/splashing
• Other Failures
  • Not available
  • Hardware failure/incorrect information
  • Unexpected reaction

Inspection vs. Mistake-Proofing

• Concepts and backgrounds on inspection
• Inspection’s limitations
• “Self-check” inspection
• “Successive-check” inspection
• Prevention always better than detection

What You Need To Know To Start Mistake-Proofing

• The language of mistake-proofing
• The role of each team member in the mistake-proofing process

Mistake-Proofing Tactics

• The eight types of mistake-proofing solutions
• How to select the approach suitable for you

Mistake-Proofing Devices

• Forced control devices
• Shutdown devices
• Warning devices
• Sensory alert devices

Mistake-Proofing Solutions

• Include mistake-proofing solutions into problem-solving procedures
• Evaluate your solutions in regards to their viability and cost-effectiveness
• How to avoid overriding your solutions
• Evaluate the robustness of your solutions
• How to complement your solutions

The TRIZ Approach

• Trimming
• Self- elimination
• Standardizing
• Copying
• Pre-action
• Color
• Combining
• Counting
• Automation

Mistake Proofing Training