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INTRODUCTION FOR POKA YOKE (ERROR PROOFING)

Poka Yoke is Japanese for error proofing. These Poka Yoke (Error Proofing) devices or systems are used either to prevent the special causes that result in defects, or to inexpensively inspect each item that is produced to determine whether it is acceptable or defective. The life and soul of production of any kind is guaranteed quality and the ultimate aim should always be zero defect.

COURSE OBJECTIVES

At the end of this course, participants will be able to :

• Explain the Poka Yoke system role in zero-defect manufacturing.
• Understand why defects occur in the production.
• Compare and select the best Poka Yoke solution.
• Overcome cultural barriers to socialize Poka Yoke.
• Start with Poka Yoke implementation.

COURSE CONTENT

Day 1

• 0900 – 1015
  • Module 1
    • Introduction to Poka Yoke system.
    • Definition of Poka Yoke.
    • Operations & processes.

1015 – 1030 : 1st Tea Break

• 10.30 – 1230
  • Module 2
    • Categories of process function.
    • Categories of the operation function.
    • 5 elements of production.
    • Defining the 5 elements.
  • Module 3
    • 4 process phenomena.
    • Shigeo’s 5 questions.
    • Separating error from defect.
    • Causes of defects.
    • Levels of defects.

1230 – 1330 : Lunch

• 1330 – 1500
• • Module 4
    • Inspection philosophies.
    • 3 methods of inspection.
    • Production efficiency and waste.
    • Types of waste.
    • Cost contributing to waste.

1500 – 1515 : 2nd Tea Break

• 1515 – 1700
• • Module 5
    • Shingo’s method.
    • Poka Yoke systems.
    • Poka Yoke devices.

Day 2

• 0900 – 1015
• • Case studies on Poka Yoke (1)
    • Poka Yoke workshop.
    • List of failure modes.
    • Finding the potential and root causes.

1015 – 1030 : 1st Tea Break

• 1030 – 1230
  • Continue Case studies on Poka Yoke (1)
    • Poka Yoke workshop.
    • Finding the corrective and preventive actions (Poka Yoke actions).

1230 – 1330 : Lunch

• 1330 – 1500
  • Case studies on Poka Yoke (2)
    • Poka Yoke workshop.
    • List of failure modes.
    • Finding the potential and root causes.

1500 – 1515 : 2nd Tea Break

• 1515 – 1700
  • Continue Case studies on Poka Yoke (2)
    • Poka Yoke workshop.
    • Finding the corrective and preventive actions (Poka Yoke actions).