COURSE OVERVIEW:

Poka-Yoke, a Japanese term meaning "mistake-proofing," is a powerful Lean technique used to design processes so that errors are either impossible to make or at least easily detected before they become defects. This course explores the philosophy that "to err is human" and provides participants with the engineering and management tools to build resilient processes. By shifting focus from reactive inspection to proactive prevention, organizations can achieve high levels of quality without increasing the burden on frontline personnel.

The scope of this training involves the practical application of Poka-Yoke devices and methods across manufacturing and service sectors. Attendees will learn to distinguish between "errors" (the cause) and "defects" (the result) and explore the various levels of error-proofing, from simple visual warnings to physical interlocks. The curriculum emphasizes the integration of Poka-Yoke into the product design phase and the use of root cause analysis to identify where error-proofing is most needed.

Coverage includes the different types of Poka-Yoke mechanisms, such as contact methods, fixed-value methods, and motion-step methods. Participants will engage in creative brainstorming sessions to solve real-world quality problems using low-cost, high-impact error-proofing solutions. By the end of the course, attendees will be able to design and implement Poka-Yoke systems that reduce scrap, eliminate rework, and foster a culture of "zero defects" within their organizations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Explain the philosophy and origins of Poka-Yoke.
• Differentiate between human errors and product defects.
• Identify common psychological and physical causes of errors.
• Classify the different types of Poka-Yoke systems (Control vs. Warning).
• Apply the three primary Poka-Yoke methods: Contact, Fixed-Value, and Motion-Step.
• Evaluate the effectiveness of different error-proofing solutions.
• Integrate Poka-Yoke into the Failure Mode and Effects Analysis (FMEA).
• Conduct a "Red Tag" analysis to identify error-prone process steps.
• Design simple, low-cost mechanical and electronic Poka-Yoke devices.
• Apply error-proofing principles to administrative and service processes.
• Facilitate a Poka-Yoke brainstorming workshop for their team.
• Measure the ROI of error-proofing in terms of quality cost reduction.

TARGET AUDIENCE:

Production Supervisors, Manufacturing Engineers, Quality Inspectors, Lean Facilitators, and Process Improvement Teams.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.