Poka-Yoke/Error Proofing

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-safing".  "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 many business cultures. 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.  Participants 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, identification and implementation of Poka-Yoke methods in the selected area.


Learning Objective

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
  • 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.


Recommended Prerequisites

  - Lean Conversion Overview    

  - 5S Workplace Organization    

  - Lean Cultural Transformation



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