This course is to introduce a systematic way to error-proof processes, stimulate creative thinking about making it impossible to make mistakes and prepare you to eliminate real-life recurring problems for good. 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 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 error or mistake proofing.
Duration: 2 Days (16 Hours)
Course Content:
- Changing trends in production and quality improvement
- Defect free production
- What is Poka-Yoke or Mistake Proofing or Error Proofing?
- Where do mistakes come from?
- Human errors: common mistakes in production
- where and when to look for mistakes
- finding the mistakes
- How to Mistake-Proof?
- purpose
- outcome
- compulsory & discretionary action
- method & devices for poka-yoke
- different categorization of Poka-Yoke systems: A, B and C
- Application of Poka-Yoke
- design – built-in error proof features
- process – shut down control and warning systems
- production – using the suitable Poka-Yoke devices to detect and avoid problem
- service – mistake proof the ‘experience’
- Practical, feasible and cost effective mistake-proofing
- Mistake-proofing steps
- identify problem
- priorities problem
- find the root cause
- create solutions
- measure the results
- FMEA and Poke-Yoke
- Zero Defects and the Role of Management
