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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:
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What Poka-Yoke is;
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The
5 elements of
product;
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The 3 basic
functions used to eliminate errors or defects;
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The 8 most common
human errors and safeguards;
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The 2 major types of
inspection;
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The
top 5
inspection techniques;
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Defects vs. Errors;
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The 2 approaches to
human error;
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Methods for developing
Poka-Yoke;
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Successful Poka-Yoke
devices; and
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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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