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INTRODUCTION FOR POKA YOKE – YOUR ULTIMATE TOOL FOR ZERO MISTAKES AND ZERO ERRORS

Mistakes and errors are becoming the talk of every day when something goes wrong. Industries, this elevates to high level as the number of people and number of machines are in large number. Most of the times when mistakes and errors happen, the training and awareness levels are blamed and immediate attention given to training and awareness. however this two only last for a few weeks and the scenario returns back.

In reality, training and awareness cannot eliminate mistakes and errors. This are just temporary actions that will contain problems from spreading. Training and awareness building are just like tonic drink ” livita “and will last only fora short period. Therefore hoping on this two will never solve the issue of mistakes and errors.

COURSE OBJECTIVE

Show participants

• Why people make mistakes.
• Why errors happen in machine operation.
• How to find out the potential that lead to making mistakes.
• How to establish the objectives of Poka Yoke.
• How to select the techniques.
• How to apply the detection tools.
• How use the Poka Yoke flow chart.

COURSE CONTENT

Module 1 : Why Poka Yoke ?

• Errors and mistakes destined or created.
• Common people mistakes.
• Common equipment errors.
• Common design short comings.
• Can all errors and mistakes eliminated – activity.

Module 2 : Introduction to Poka Yoke.

• Definition of Poka Yoke.
• History of Poka Yoke.
• Concept of Poka Yoke.

Module 3 : Poka Yoke approach.

• Determine the purpose.
• Establish the technique.
• Select the detection tool.
• Poka Yoke flow chart.

Module 4 : Eliminate human induced mistakes .

• Why humans make mistakes.
• Understanding the root cause.
• Determine the purpose.
• Techniques for eliminating human mistakes.
  • Technique 1 : Guide pin / block method.
  • Technique 2 : Asymmetry principle.
  • Technique 3 : Counters
  • Technique 4 : Color codes
  • Technique 5 : Checklists.

Module 5 : Prevent unexpected equipment errors.

• Why errors occur in equipments.
• Understand the weaknesses.
• Determine the purpose.
• Techniques for eliminating equipment errors.
  • Technique 6 : contact methods
  • Technique 7 : contact-less methods.
  • Technique 8 : condition monitor methods
  • Technique 9 : operational changes.
  • Technique 10 : environment changes.
  • Technique 11 : error detection programs.

Module 6 : Make systems fool-proof always.

• Common system errors.
• Understanding the root causes.
• Techniques for eliminating system errors
  • Technique12 : asymmetry methods ( shape )
  • Technique13 : go – no go methods ( fitting )
  • Technique14 : electronic control methods
  • Technique15 : early warning methods
  • Technique16: immediate shut down methods.

Module 7 : Evaluate Poka Yoke solutions .

• Negative box-paradigm
• Common mental blocks.
• Idea generation for Poka Yoke.
• Guidelines for idea selection.
• Golden rule of Poka Yoke- keep it simple

HOW TO ENQUIRY FROM US?

1. Fill in the form below and submit to us.
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