INTRODUCTION FOR APPLYING POKA YOKE TECHNIQUES

Poka Yoke is a Japanese phrase that translates to error prevention. A Poka is an unintentional error, and Yokeru is Japanese for preventing, is the lean manufacturing tool which forms the basis of the Zero Quality Control (ZQC) system for avoiding and eliminating mistakes, defects and errors.

Developed 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.

Inspection is the most important element of quality control, is to detect faulty products from non-faulty products, increasing the level of inspection may improve outgoing quality levels and help with controlling processes in high defect levels, it won’t prevent defects from occurring.

How can we make errors, defects and mistakes either so visible that we can detect them at source or even better eliminate them altogether?

COURSE OBJECTIVES

• Understand the goal and importance of mistake proofing
• Apply mistake proofing methods and techniques in their work to reach the zero defects process quality
• How Do We Achieve ZDQ
• Identify the source of mistakes, difference between mistakes, errors and defects
• 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

COURSE CONTENT

Module 1 : Overview To Mistake-Proofing

• What is mistake proofing or Poka Yoke?
• How to find the source of mistakes
• How to set a mistake-proofing mindset among your organization
• Zero Quality Control (ZQC)
• Basic functions of Poka Yoke
• Poka Yoke culture
• Positive and negative cultures
• Class Exercise
  • Daily Life Mistake-Proofing Solutions
  • Find examples of mistake-proofing around you
  • How to get ideas from them at work

Module 2 : Defects And Costs

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

Module 3 : Definition and concept

• How ZDQ makes your work easier
• How to achieve ZDQ
• Components of ZDQ
  • Inspection
  • Audit checks
  • Immediate feedback
  • Poka Yoke

Module 4: Principals Of Mistake-Proofing

• Importance of identifying root causes of mistakes
• Common mistakes causing defects
• Common defect categories
• Ten Types of Human Mistakes
• Preventing mistakes
• Elimination
• Replacement
• Facilitation
• Minimizing the effects of mistakes after they are made
• Detection
• Mitigation

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