GEMBA KAIZEN TRAINING INSTITUTE

Poka Yoke Training

Poka-Yoke is a technique used for avoiding and eliminating mistakes. Dr. Shingo wrote the book "Zero Quality Control: Source Inspection and the Poka-yoke system" in 1986. This original source material defined the basic approach. However, the technique has been extensively developed since..

Poka-Yoke is a proofing technique, which is the basis of the Zero Quality Control (ZQC) approach. Generally this technique is used in manufacturing process but has much wider uses, such as; offices - order and invoice processing, hospitals - drug dispensing, aircraft maintenance - particularly with processes having the potential of catastrophic in-service failures..

is derived from ‘Poka’ - inadvertent mistake and ‘yoke’ - avoid. Of course, the concept of proofing processes and mechanical devises has been around for many years (e.g. see photographs of floppy disk drive and electrical plugs) but is was the Japanese Matsushita Industrial Engineer Dr. Shigeo Shingo who was probably most prominent and influential in developing it into a technique. He turned the idea into a powerful approach for eliminating mistakes and achieving zero defects.

Benefits
To enable delegates to:
• Understand and implement the “Poka-Yoke" methodology
• Understand and practically employ the basic techniques associated with Zero Quality Control (ZQC) and Poka-Yoke.
• Identify where ZQC and Poka-Yoke can be used for best effect
• Coordinate and motive the Poka-Yoke team to provide real, tangible solutions to what appear to be intractable quality problems.
• Train others in the ZQC and Poka-Yoke methodology.

Workshop Goals
• Understand the philosophy, history and benefits of Mistake Proofing
• Understand how Mistake Proofing fits into a modern quality management system
• Develop your ability to plan and deploy Mistake Proofing methods to achieve significant reductions in defect rates

Workshop Outline
• History of Mistake Proofing
• Relationship between Operating Conditions, Mistakes and Defects
• Mistake Proofing and APQP Process
• Prevention versus Detection Systems
• Mistake Proofing Development Process
• Mistake Proofing Toolbox
• Creative and Structured Problem Solving
• Evaluating Mistake Proofing Systems
• Closing the Loop – Mistake Proofing and APQP
• Performance Management and Mistake Proofing


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