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.
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
Level of People
- Supervisor, Senior People from shop-floor
- Entry Level and Middle-Level Managers
- 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?
- Physical contact design
- Sequence control design and
- Constant number design
Evolution of Defect Control
- Prevention and
- Project Identification
- Cause & Effect Analysis
- Choosing right design & mechanism
- Classroom sessions
- Observations: Audio-visual
- Playing: Poka-yoke games & Quiz
1 Day – 8 Hours
Min 10 and Max 20 Participants per batch
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