Error/Mistake Proofing
(Poka' Yoke)

Poka Yoke

Mistake proofing, error proofing or Poka Yoke, it doesn't matter what someone calls it. What matters is this is one of the most effective methods to reduce product and process defects.

Study data shows excessive process input variation is the largest cause of manufacturing quality problems  This often times results from the fact that most manufacturing processes rely on people. And, people are the single greatest source of variation.

Variation compensation

Mistake proofing compensates for the variation caused by people. It does not rely on people for quality. Mistake proofing is one of the most effective cost savings methods for improving quality.

Mistake proofing methods

There are two methods of mistake proofing, the warning method and the control method. The control method is the most effective. The control method automatically stops the process when a defect is detected or separates the defective from good product.

The warning system alerts the operator that something is wrong. It does not stop the operation or separate defect from good product. Defects could occur if the operator ignores the warning. This happens because of the number of false-positive warnings given in the past.

Corrective Action compliant

This course helps you comply with the corrective action clause (8.5.2) of ISO 9001:2000, AS9100:2004 and ISO/TS 16949:2002

You can have this class presented at your business for as little as $65. per person. Call us or click on the 'Contact Us' links on this page.

Course content

This class is 1 day and includes:

1.      Introduction and overview

2.      Review of improvement strategies

3.      Defect sequence: root cause, error, defect

4.      Breaking the sequence

5.      Mistake proofing the operation

6.      Implementation of mistake proofing

7.      Workshops

8.      CEU and RU credits are awarded