Poka-Yoke Workshop

CSense - Poka-Yoke Training

Poka-yoke One day program

What is Poka-Yoke?

Poka-Yoke is a Japanese term meaning Mistake-proofing. Developed by Shigeo Shingo at Toyota Motors in Japan. This protects the process from the mistakes. The concept is to prevent mistake becoming defects and reaching customers – by building detection mechanisms within the processes.

Need for Poka-Yoke

In today’s world Quality is the only distinction between existence and extinction of a business. The Product Quality is no longer an advantage. Customers expect the highest quality, always and it has become a must-be requirement today.

We do not have a luxury of responding to customer complaints and awaiting their feedback. They have multiple options to choose and they do so at the first instance of dissatisfaction.

Poka-Yoke makes people in the organisation that Zero-Defect is Possible! This is the first step towards achieving Zero Defects and even Zero Accidents.

Attrition and scarcity of resources are becoming perennial problems of the organisation. Poka-Yoke is a vital solution to these problems. By principle, it adds skill to the processes and the machines, leading to efficient and defect-free operations.CSense Poka-Yoke Training


Mistake proofing is one of the vital parts of TPS family. The Toyota Production System is supported by the 3 pillars namely, Just-in-Time, Built-in Quality and People Involvement.

Poka-Yoke is the major mechanism of achieving built-in quality.

Benefits to Organisation

  • Reduce customer complaints
  • Get rid of recurring problems and failures
  • Prevent losses due to defects
  • Make your workplace safer
  • Start your journey towards zero-defects and zero-accidents

Target Audience

Level of People

  • Supervisor, Senior People from shop-floor
  • Entry Level and Middle-Level Managers


  • Production
  • Quality
  • Maintenance
  • Development


  • Manufacturing
  • Engineering
  • Automobile
  • Chemical
  • Pharma
  • Food
  • FMCG
  • Services

Course Contents


  • What is Business?
  • Why are customers paying money?
  • Why keep customers happy?
  • What is Quality & Productivity?

Overview of Business Improvement Initiatives

What is Built-in Quality

  • The philosophy
  • What is Mistake-Proofing

What do you measure?

  • Maturity of Organisation with respect to Quality & Inspection
  • 3 stages of inspection
  • What are the defects?
  • What is a mistake and what is a defect?

Poka-Yoke Designs

  • Physical contact design
  • Sequence control design and
  • Constant number design

Poka-yoke Mechanisms

  • Warning
  • Control
  • Shut-down

Evolution of Defect Control

  • Detection
  • Prevention and
  • Prediction

Zero-Defect Projects

  • Project Identification
  • Cause & Effect Analysis
  • Choosing right design & mechanism

Training Methodology

Learning by

  • Classroom sessions
  • Observations: Audio-visual
  • Playing: Poka-yoke games & Quiz

Course Duration

1 Day – 8 Hours

Batch Size

Min 10 and Max 20 Participants per batch

Additional Support

Continued coaching and hand-holding support could be provided by CSense after the workshop for successful project completion, as an optional engagement. We can also extend the support in other areas