Course Description
This hands-on Poka Yoke (Error Proofing) course (1 or 2 days) equips participants with the knowledge and skills to design and implement mistake-proofing methods that prevent errors before they occur. By applying Poka Yoke principles, organizations can dramatically reduce defects, improve quality, and increase customer satisfaction.
Through interactive exercises, practical examples, and real-world application, participants will learn how to identify error-prone processes, develop effective error-proofing devices or methods, and integrate these solutions into daily operations. The course emphasizes the financial benefits of Poka Yoke, including reduced scrap and rework costs, fewer warranty claims, improved process reliability, and measurable cost savings.
Course Objectives
Understand Poka Yoke Principles:
– Define Poka Yoke and its role in Lean quality improvement.
– Recognize different types of error-proofing methods and devices.
Identify and Analyze Error-Prone Processes:
– Conduct root cause analysis to uncover sources of human or process errors.
– Prioritize error-proofing opportunities based on risk and cost impact.
Design and Implement Error-Proofing Solutions:
– Develop low-cost, effective methods to prevent or detect errors.
– Integrate Poka Yoke solutions into standard work and process design.
Link Poka Yoke to Financial Performance:
– Quantify cost savings from reduced defects, scrap, and rework.
– Connect error-proofing improvements to ROI and customer satisfaction.
Sustain and Improve Poka Yoke Systems:
– Audit and refine error-proofing methods to ensure continued effectiveness.
– Engage employees in identifying and implementing new Poka Yoke ideas.
Training Format Options
– 1-Day: Introduction to Poka Yoke concepts, identification of error-prone processes, and development of sample error-proofing solutions.
– 2-Day: Expanded training with in-depth process analysis, real-world application, and implementation planning for workplace-specific solutions.
