Introduction

Mistake-Proofing, or Poka-Yoke, is a technique used in various industries to prevent errors and defects in products and processes. This 5-day professional course aims to equip participants with the knowledge and skills to implement Poka-Yoke techniques effectively in their organizations, ensuring quality and efficiency in operations.

Objectives

• Understand the principles of mistake-proofing and its importance in quality management.
• Learn how to identify potential errors in processes and their root causes.
• Explore various Poka-Yoke techniques and tools to prevent mistakes.
• Develop skills to design and implement effective mistake-proofing solutions.
• Gain insights into maintaining and continuously improving mistake-proofing systems.

Course Outlines

Day 1: Introduction to Mistake-Proofing

• Overview of Poka-Yoke and its history
• The role of Poka-Yoke in Lean Manufacturing
• Common types of errors in processes
• The cost and impact of errors in production
• Case studies of successful mistake-proofing implementations

Day 2: Identifying Errors and Root Causes

• Techniques for error detection in processes
• Understanding root cause analysis
• Using the 5 Whys technique for problem identification
• Creating a mistake-proofing mindset in teams
• Workshop: Identifying errors in a given process scenario

Day 3: Mistake-Proofing Techniques and Tools

• Introduction to various mistake-proofing devices
• Physical, sequencing, and use-related error-proofing
• Designing effective error prevention mechanisms
• Utilizing technology for mistake-proofing
• Group activity: Design a mistake-proofing tool for a specific process

Day 4: Implementation of Mistake-Proofing Solutions

• Steps for implementing Poka-Yoke techniques
• Incorporating mistake-proofing in the design phase
• Monitoring and measuring effectiveness of solutions
• Overcoming resistance to change
• Practical exercises: Role-playing various implementation scenarios

Day 5: Maintaining and Improving Mistake-Proofing Systems

• Continuous improvement methodologies
• Regular assessment and feedback mechanisms
• Case examples on evolving mistake-proof systems
• Future trends in mistake-proofing and quality control
• Course wrap-up and participant presentations