Price: $1,699.00

Length: 2 Days
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Mistake Proofing Training, Poka Yoke

Poka yoke is a Japanese phrase that translates to error prevention. A “poka” is an “inadvertent error,” and “yokeru” is Japanese for “preventing.”

The idea behind poka yoke is to make it nearly impossible to make mistakes before they occur. It was developed in the sixties of the previous century by Shigeo Shingo, a Japanese engineer at the Toyota car factory. Toyota is still the most famous multinational business using poka yoke today, although poka yoke is commonly known outside Japan as mistake proofing.

Mistake proofing forces actions to be carried out correctly, leaving no room for misunderstandings. It’s about measures that prevent further errors from being made.

The true brilliance of this mistake proofing methodology is in its simplicity. These often cheap and effective solutions can be integrated into the product design or in one of the process steps.

In general, mistake proofing objectives should have three major attributes:

  • Effectiveness – Does the new design change reduce the frequency with which the errors occur?
  • Inexpensive – The idea behind mistake proofing is to implement or reduce simple steps to resolve common errors.
  • Easily implemented – Ideally you want to introduce design changes that are easy to accomplish without employee resistance.

When applying the poka yoke methodology it’s important to build a cross functional team to review the process. The mistake proofing team should consist of workers, quality technicians, manufacturing engineers, quality engineers and production supervisors among others. Each member of the team should have received proper training in mistake proofing or error proofing methods and possess a thorough knowledge of the process to be reviewed, including any history of process errors or product defects.

The procedures used in poka yoke vary from company to company, but normally follow a similar pattern. A flowchart, for instance, is generally created documenting where and when human errors are likely to occur in a process. For each potential error, the mistake proofing team works back through the process to find the source of the error.

When each error is detected, the mistake proofing team then needs to come up with potential solutions to fix the errors. The choices generally fall into three categories:

  1. Elimination (the step that caused the error is done away with)
  2. Replacement (the step with the error is replaced with an error-proof one)
  3. Facilitation (this involves making the correct action much easier than the error)

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. Mistake Proofing Training, Poka Yoke 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:

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

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