Course Information

Mistake-Proofing Training

Learners will be able to:

Describe mistake-proofing effects, outcomes, and solutions.
Use mistake-proofing techniques to eliminate process and product problems.
Integrate mistake-proofing into the overall Quality Improvement Process.

About This Course

What is Mistake-Proofing (Poka Yoke)?

Mistakes seem to happen at the worst time. At work, just before a critical shipment, an inadvertent mistake causes the entire shipment to be rejected. Or at home, just before leaving for a long anticipated vacation, “Murphy’s Laws” intervene, and a series of seemingly unavoidable mistakes delays our departure.

Can we defeat Murphy’s Laws? Can we eliminate these costly mistakes? Probably not totally, but the use of mistaking-proofing tools and techniques will put an end to many of the repetitive, costly mistakes that rob us of time and money both at home and at work.

Mistake-Proofing is more than just incremental improvements or trying harder to do a better job. Mistake-Proofing techniques don’t just reduce the chance of making errors, but they eliminate the possibility for error altogether.

Mistake-Proofing Online Training

Mistake-Proofing online training will help put you on the path to defeating Murphy’s Laws. With Mistake-Proofing, you will not only learn a systematic way to error-proof processes and products, but you will also see a wealth of examples of mistake-proofing solutions applied to real-life recurring problems. Most people learn mistake-proofing skills by seeing examples and then stealing shamelessly to apply similar solutions to their own problems. That’s why Mistake-Proofing is loaded with lots of examples that will trigger implementation of more mistake-proofing solutions in your company. Check out Error-Proofing Support Processes if you are looking for Mistake-Proofing training in a non-manufacturing setting.

Mistake-Proofing is divided into four units. Unit 1, The Mistake-Proofing Primer provides a conceptual background and foundation for mistake-proofing efforts. Unit 2, Effects of Mistake-Proofing, covers practical mistake-proofing techniques. Tools to design and implement mistake-proofing solutions are covered in Unit 3, Mistake-Proofing Solutions. Examples of problems along with accompanying mistake-proofing solutions in a variety of settings are explored in Unit 4, Mistake-Proofing in Action.

Price: See Pricing

Type of Course: Master Course (1 Training Credit/Learner)

Certificate of Completion: Yes

Continuing Education Units: 0.8 CEU’s/RU’s

Time to Complete: Approximately 8.0 Hours

Audience: Front Line Employees, Engineers, Quality Professionals, Managers

Prerequisites:

None.

Languages:

English (EN-US)
Chinese (simplified) (ZH)
Czech (CS)
French (FR)
German (DE)
Italian (IT)
Japanese (no audio) (JA)
Korean (no audio) (KO)
Polish (PL)
Portuguese (Brazilian) (PT-BR)
Romanian RO)
Russian (RU)
Spanish (ES)
Vietnamese (no audio) (VI)

Course Objectives

Unit 1 | Mistake-Proofing Primer

Understand the goal of mistake-proofing.
Know the language of mistake-proofing.
Recognize mistake-proofing solutions in everyday life and use these solutions as triggers for ideas to mistake-proof your processes.
Identify the five process input elements that exist in any process.
Recognize why errors are made.
See the value of improving processes so that mistakes are prevented instead of relying on inspection to find mistakes.

Unit 2 | Effects of Mistake-Proofing

Be able to rank the relative power of the different forms of mistake-proofing effects.
Recognize a forced control effect. Be able to apply:
- Elimination
- Combination
- Guides
- Process control

Have an understanding of some of the types of sensors available to achieve a shutdown effect.
Have an understanding of some of the types of devices available to create a mistake-proofing solution using a warning effect.
Know how to apply sensory alert effects to mistake-proofing.

Unit 3 | Implementing Mistake-Proofing Solutions

Learn to apply mistake-proofing solutions after the root cause has been found.
Be able to evaluate whether the mistake-proofing solution is practical, feasible, and cost-effective.
Learn how to build-in ways to assure your solution does not get overridden.
Evaluate the robustness level of your solution.
Become familiar with 10 improvement tools that complement the mistake-proofing process.

Unit 4 | Mistake-Proofing in Action

In this unit, recurring problems from a variety of industrial settings are explored and successful mistake-proofing solutions are shown. The problems come from the following industrial settings:

High volume manufacturing.
Assembly operations.
A job shop environment.
Process industries.
Equipment set-up.
In the office.

The primary objective of this Unit is to expose you to a variety of mistake-proofing solutions to help you develop your own mistake-proofing solutions.

The secondary objective is to help you think through the solution presented and then identify what type of solution has been used.

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Course Outline

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.

Unit 1 Challenge

An assessment of the learner’s progress in this unit.

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

Examining 10 common families of sensors used to achieve a shutdown effect.

Lesson 4 | Warning Devices

Investigating 4 families of audible alarms and 4 families of visual alarms used to achieve a warning effect.

Lesson 5 | Sensory Alert Devices

A look at the use of color-coding, missing-in-action clues, and other aids to achieve a sensory alert effect.

Unit 2 Challenge

An assessment of the learner’s progress in this unit.

Unit 3 Implementing Mistake-Proofing Solutions

Lesson 1 | Integrating Mistake-Proofing and Problem Solving

How to incorporate mistake-proofing solutions into common problem-solving processes.

Lesson 2 | Practical, Feasible, and 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.

Unit 3 Challenge

An assessment of the learner’s progress in this unit.

Unit 4 Mistake-Proofing in Action

Lesson 1 | Mistake-Proofing in High Volume Manufacturing

Nowhere are the benefits of mistake-proofing more evident than in high volume operations.
8 real-life examples of mistake-proofing solutions in a high volume environment.

Lesson 2 | Mistake-Proofing in Assembly Operations

Mistake-proofing is a perfect tool to prevent assembly errors.
8 real-life examples of mistake-proofing solutions in assembly operations.

Lesson 3 | Mistake-Proofing in a Job Shop Environment

Mistake-proofing in short-run job shops can make the difference between profitability and bankruptcy.
8 real-life examples of mistake-proofing solutions in a job shop environment.

Lesson 4 | Mistake-Proofing in Process Industries

Mistake-proofing is at the core of complex chemical operations.
8 real-life examples of common sense mistake-proofing solutions from the process industry that can trigger ideas to simplify your operation.

Lesson 5 | Mistake-Proofing in Equipment Set-up

Mistake-proofing is an important element of set-up reduction.
8 real-life examples of mistake-proofing solutions to aid equipment set-up and speed product change-overs.

Lesson 6 | Mistake-Proofing in the Office

Mistake-proofing is not just for plant operations.
8 real-life examples of mistake-proofing solutions in the office.

4.6 out of 5 stars

Comments from Learners About This Course

Good course; used what I learned already.
Very practical.
Nice course. Really helped me learn the different types of pokayoke.
I really enjoyed this training – very detailed with great examples and info for further project planning.
It helped me with determining which way to go while I’m dealing with an issue or an ongoing issue to help resolve the problem all together.
The course did a great job at identifying and categorizing different mistake proofing methods.
I found this course very helpful in understanding mistake-proofing. The content was explained in a clear and easy to understand manner. Many examples were reviewed to provide an understanding of the different mistake-proofing solutions.
As someone who is working in the Automotive Industry; This course was a great insight into mistake proofing techniques, I loved and enjoyed every minute of it. I will surely be back for more courses along this line.