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Lean Manufacturing
Welcome to Poka-Yoke (Error Proofing)

Poke-YokeDr Shingo, the inventor of single minute exchange of dies (SMED) is credited with the invention of the poka-yoke system. The word itself means “mistake proofing” in Japanese. Poka-yoke is simply is a combination of ingenious devices (fixtures, sensors) that are used in a production process to prevent any fault occurring in that particular process. If a fault does occur, the operator is notified immediately. Shingo proposed the use of a poka-yoke system along with 100% source inspection to ensure “zero defects”. Poka-yoke devices are designed to stop faults occurring in the process and if they do occur, the operator is given a warning signal so that he or she can take corrective action. Poka-yoke systems recognise that human beings are fallible.

Poka-yoke systems are classified by Shingo into two major groups:

    1. Poka-yoke for regulatory functions. There are sub-grouped into:

    • Control methods, which, when abnormalities occur, shut down machines or lock clamps to halt operations, thereby preventing the recurrence of errors or defects; and
    • Warning methods, which call abnormalities to workers’ attention by activating a buzzer or a light.

    2. Poka-yoke for setting functions. There are sub-grouped into:

    • Contact methods, which detect abnormalities in product shape or dimension by determining whether or not contact is made between the products and the sensing devices;
    • fixed value methods, which detect abnormalities by checking for the specified number of motions in processes where operations must be repeated a predetermined number of times; and
    • motion-stop methods, which detect abnormalities by checking the errors in standard motions in processes where operations must be carried out with predetermined motions.
 
Endorsed Presentation: Poka-Yoke

Poka Yoke PowerPoint Training Presentation
This professionally-developed presentation is designed as a 40-60 minute overview of the topic. Many customers use the presentation as part of a group learning event, individual training at a computer, or as foundation slides for a more detailed or customized training presentation.

The presentation is delivered in native Microsoft PowerPoint format for easy customization. All slides may be changed to accommodate your desired use. The only restriction is that the presentation cannot be resold without permission of Superfactory.
  • Number of slides: 51
Table of Contents:
  • Introduction
  • Background & History\
  • What is a Poka Yoke?
  • Everyday Examples
  • Error Proofing and SPC
  • Inspection Techniques
  • Types of Poka Yokes
  • Knowledge Check

Lean Office Poka Yoke PowerPoint Training Presentation
This professionally-developed presentation is designed as a 40-60 minute overview of the topic. Many customers use the presentation as part of a group learning event, individual training at a computer, or as foundation slides for a more detailed or customized training presentation.

The presentation is delivered in native Microsoft PowerPoint format for easy customization. All slides may be changed to accommodate your desired use. The only restriction is that the presentation cannot be resold without permission of Superfactory.
  • Number of slides: 67
Table of Contents:
  • Introduction
  • What is Mistake Proofing and Poka Yoke?
  • Everyday Examples
  • Effectiveness and ROI
  • Poka Yoke and SPC
  • Inspection Techniques
  • Types of Poka Yokes

Poka Yoke PowerPoint Training Presentation
This professionally-developed presentation is designed as a 40-60 minute overview of the topic. Many customers use the presentation as part of a group learning event, individual training at a computer, or as foundation slides for a more detailed or customized training presentation.

The presentation is delivered in native Microsoft PowerPoint format for easy customization. All slides may be changed to accommodate your desired use. The only restriction is that the presentation cannot be resold without permission of Superfactory.
  • Number of slides: 75
Table of Contents:
  • Introduction
  • What is Mistake Proofing?
  • Everyday Examples
  • Effectiveness and ROI
  • Poka Yoke and SPC
  • Inspection Techniques
  • Types of Poka Yokes

Poka Yoke (Error Proofing) Package

Poka Yoke (Error Proofing) is the use of a device or method makes it impossible for an error to occur or to make the obvious error in the process. The ChartitNOW package contains the following:
  • Poka-Yoke Instructions
  • Mistake Proofing Analysis Form

Error-Proofing Business Processes Course Outline -- 10 Lessons

Error-Proofing Business Processes is a computer-based training course designed specifically for those working in offices and transactional environments. This course explores how to error-proof the transactional processes by studying both the server-side (service provider) and the customer-side of the transaction. Techniques to uncover the root cause of errors and then prevent their recurrence are covered. With Error-Proofing Business Processes, you will not only learn a systematic way to error-proof processes and services, but you will also see many of examples of error-proofing solutions applied to real-life recurring problems. Most people learn error-proofing skills by seeing examples and then applying similar solutions to their own problems. That's why Error-Proofing Business Processes is loaded with examples. We hope these examples will trigger implementation of more error-proofing solutions in your organization. The Error-Proofing Business Processes training program consists of two Units each with five Lessons and a Challenge (assessment test) designed to test the learner's comprehension of the body of knowledge covered in that Unit.

Target Audience Business support staff and management, office workers and other non-manufacturing personnel. Those who are in direct manufacturing or manufacturing management roles may also want to consider the Mistake-Proof It.

Course Length The estimated time to complete the course is 5 hours however the amount of time a learner spends on the course is learner controlled and is therefore variable.

Course Objectives Upon completing this course, learners should be prepared to: • Understand the goal and language of error-proofing. • Recognize error-proofing solutions in everyday life and use these solutions as triggers for ideas to error-proof transactional processes. • Be familiar with the transactional model of a process and understand how errors can be introduced from the service provider's side and from the customer's side of the transaction. • See the value of improving processes so that errors are prevented instead of relying on detection to find errors. • Be aware of common techniques for achieving all four types of error-proofing effects. • Have a basic understanding of how to identify the root cause of errors and address root causes of errors by develop error-proofing solution candidates and evaluate candidates to determine the best solution for the situation. • Understand how the Seven Wastes represent chronic process errors and why these chronic errors are as important to address as acute errors

Unit 1 - Error-Proofing Primer Lesson 1: The Error-Proofing Mindset • Understand the error-proofing mindset. • Recognize that to error-proof a process or system the root cause of errors must be found and addressed. Lesson 2: Error-Proofing in Everyday Life • Be aware of examples of common error-proofing in action in everyday life. • Understand that error-proofing does not require elaborate efforts or complex systems. Lesson 3: Why Errors Are Made • Realize that errors are usually due to process problems, not people problems. • Become familiar with the transactional model of process and some of the complexities. Lesson 4: How Transactions (Can) Go Wrong • Understand some of the reasons transactional processes tend to be so complex. • View errors by service providers into the categories of tasks, treatment and detractors/attractors and by customers into groupings of preparation, encounter and resolution. Lesson 5: How Error-Proofing Works • Become familiar with error-proofing effects, outcomes and solutions. • Understand how error-proofing solutions are best developed in a team environment using a structured, data-driven problem-solving approach. Challenge • An assessment of the learner's understanding of the body of knowledge

Unit 2 - Effects of Mistake-Proofing Lesson 1: Forms of Error-Proofing Solutions • Know that error-proofing solutions are a combination of effects and outcomes. • Be aware of common techniques to achieve each of the four types of effects. Lesson 2: Error-Proofing Solutions • See how error-proofing solutions are best developed using a team problem-solving process. • Be familiar with establishing team roles and responsibilities and how to clarify the problem. • Understand how to focus on the root cause. • Know how to formulate an error-proofing solution and develop an action plan to implement it. Lesson 3: Evaluating Solutions • Learn how to evaluate whether solution candidates are practical, feasible and cost-effective. • Be able to evaluate the robustness of solution candidates. Lesson 4: Error-Proofing & the Seven Wastes • Recognize the Seven Wastes as chronic, hidden form of errors. • Recognize the Seven Waste in terms of the Transactional Process Model with both server-side and customer-side causes. Lesson 5: Complementary Error-Proofing Tools • Learn how to apply the Five-Whys, Comparative Analysis, Timeline Analysis and Cause & Effect Diagrams as error-proofing investigative tools. • Become familiar with how additive data picture tools help paint a picture of the problem.

Challenge • An assessment of the learner's understanding of the body of knowledge

Mistake-Proof It! Course Outline -- 4 Units

Unit 1 - Mistake-Proofing Primer Lesson 1: What is Mistake-Proofing? · Rewriting Murphy's Laws. · Exploring the source of mistakes. · The mindset necessary for mistake-proofing. Lesson 2: Mistake-Proofing in Everyday Life. · Common examples of mistake-proofing all around us. · Using these examples to trigger ideas at work. Lesson 3: Why Errors Are Made. · How process inputs create process outputs. · Why the root causes of errors must be identified. Lesson 4: Inspecting vs. Mistake-Proofing. · The limitations of inspection. · Why prevention is always more powerful than detection. Lesson 5: How Mistake-Proofing Works. · The language of mistake-proofing. · The role of teams in mistake-proofing efforts. Challenge: An assessment of the learner's progress in this unit.

Introduction to Lean Six Sigma introduces the fundamentals of Lean Six Sigma providing a comprehensive understanding of what it is, background on the improvement methodologies used in a Six Sigma Process, important details on the necessary supporting infrastructure and provides examples of Lean Six Sigma in manufacturing, the office, order entry, warehousing and distribution, sales and R&D.

Unit 2 - Effects of Mistake-Proofing Lesson 1: Approaches to Mistake-Proofing. · Exploring the 8 forms of mistake-proofing solutions. · Guidelines for selecting a mistake-proofing approach. Lesson 2: Forced Control Devices. · Delving into the four families of devices and methods used to achieve a forced control effect. Lesson 3: Shutdown Devices & Warning Alarms. · Examining 10 common families of sensors used to achieve a shutdown effect. · Investigating 4 families of audible alarms and 4 families of visual alarms used to achieve a warning effect. Lesson 4: Sensory Alert Devices. · A look at the use of color-coding, missing-in-action clues, and other aids to achieve a sensory alert effect. Challenge: An assessment of the learner's progress in this unit.

Unit 3 - Implementing Mistake-Proofing Solutions Lesson 1: Integrating Mistake-Proofing & Problem Solving. · How to incorporate mistake-proofing solutions into common problem-solving processes. Lesson 2: Practical, Feasible, & Cost Effective Solutions. · Assessment techniques for determining the practicality, feasibility, and cost-effectiveness of your mistake-proofing solutions. Lesson 3: How to Keep Solutions from Being Overridden. · Tips for keeping your mistake-proofing solution from being ignored or disabled. Lesson 4: How Robust is Your Solution? · Assessment techniques for determining how robust your mistake-proofing solutions are. Lesson 5: Complementary Tools. · How to use ten continuous improvement tools to complement mistake-proofing efforts. Challenge: An assessment of the learner's progress in this unit.

Unit 4 - Mistake-Proofing in Action (Eight real-life examples in a variety of settings.) Lesson 1: Mistake-Proofing in High Volume Manufacturing. · Nowhere are the benefits of mistake-proofing more evident than in high volume operations. Lesson 2: Mistake-Proofing in Assembly Operations. · Mistake-proofing is a perfect tool to prevent assembly errors. Lesson 3: Mistake-Proofing in a Job Shop Environment. · Mistake-proofing in short-run job shops can make the difference between profitability and bankruptcy. Lesson 4: Mistake-Proofing in Process Industries · Mistake-proofing is at the core of complex chemical operations. Lesson 5: Mistake-Proofing in Equipment Set-up. · Mistake-proofing is an important element of set-up reduction. Lesson 6: Mistake-Proofing in the Office. · Mistake-proofing is not just for plant operations. Challenge: An assessment of the learner's progress in this unit.


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