Poka-Yoke
2 day (workshop) / Implementation based on project
Human beings tend to be very forgetful and because of this,
make a lot of mistakes. Usually, we blame the people who made
the mistakes for their errors. The problem with this approach is
that it discourages the work force and lowers morale. More
significantly, it does not even begin to solve the problem and
fosters "finger-pointing." Poke-Yoke is a way to address the
issue of reducing human errors at work. Shigeo Shingo, a
Japanese manufacturing engineer, developed the idea of
"fool-proofing" into this formidable tool for achieving "zero
defects." In this way we can move toward the elimination of
quality control inspections.
The translation of Poka-Yoke in general terms is
"mistake-proofing" or "fail-safeing." Yoke means to avoid and
Poka means inadvertent errors. To become a world-class
competitor, an organization must adopt not only a philosophy,
but also a practice of producing zero defects—Poka-yoke is a way
to achieve this. Conceptually, it is not difficult. In practice,
however, everyone in the company needs to be involved and often
this concept is foreign to American business culture. Just
imagine your company's potential if all errors were eliminated.
How successful would you be?
Course Description:
Participants will be trained in the many ways to prevent errors
at the source using the “error-proofing” or “Poka-Yoke” methods.
You will gain insight about this important approach and shown
where to look for error-proofing opportunities to achieve zero
defects. We will also show you how to implement automatic and
manual principles of error-proofing, as well as techniques such
as “layering”. The process includes the development of
procedures and the identification & implementation of Poka-Yoke
methods in the selected area.
Learning Objectives:
After completion of this course participants will have an
understanding of:
• What is Poka-Yoke;
• The 5 elements of product;
• The 3 basic functions used to eliminate errors or defects;
• The 8 most common human errors and safeguards;
• The 2 major types of inspection;
• The top 5 inspection techniques;
• Defects vs. Errors;
• The 2 approaches to human error;
• Methods for developing Poka-Yoke;
• Successful Poka-Yoke devices; and
• The 8 principles of basic improvement for Poka-Yoke and zero
defects.
Who Should Attend:
If the ultimate goal is to reach zero defects, then everyone in
the organization must be involved. Poka-Yoke requires the ideas,
thoughts, and actions of whoever is the closest and most
knowledgeable about the product or process.
Prerequisites:
- Lean Conversion Overview
- 5S Workplace Organization
- Lean Cultural Transformation
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