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.

Philosophy

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

Functions

• Production
• Quality
• Maintenance
• Development

Industry

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

Course Contents

Orientation

• 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