WORKSHOP SYNOPSIS:

Mistake-proofing, or as the Japanese call it – poka yoke, is one of the key tools that drives the highly successful Toyota Production System. It has also emerged as one of the tools required by the automotive industry. The automotive industry has targeted the application of mistake-proofing by their suppliers as critical to their success. They have found that even suppliers with processes producing parts with extremely high capability indices (that predict defect levels in the parts per billion), produce bad parts when a mistake occurs.

In its optimal form, mistake-proofing eliminates the chance of a mistake occurring. Even where the chance of a mistake can’t be totally eliminated, mistake-proofing techniques can make it easy to do the job right in the first place. Mistake-proofing techniques can be learned and practiced by all levels of the organization.

Mistake-proofing a process typically leads to extremely fast payback on the investment. This includes the training/facilitation investment. We find that companies investing in mistake-proofing training for their employees will usually pay for the training costs within 4 to 6 months. Many companies have actually paid for the cost of the training with mistake-proofing ideas identified right in our workshop and implemented immediately afterwards.

Course Contents

• What is mistake-proofing?
• Types of errors (mistakes)
• Why errors occur
• Preventing errors from occurring
• Mistake-proofing solutions
• Forced Control
• Shutdown
• Warning
• Sensory Alert
• Mistake-proofing power
• Ensuring a solution is robust
• How to implement mistake-proofing