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Increase " First Time Right and Every Time Right "Consciousness in Process Through A Pokayoke Workshop
Increase " First Time Right and Every Time Right "Consciousness in Process Through A Pokayoke Workshop
Envisionment:
Increase " First time right and every time right "consciousness in Process
through a Pokayoke workshop
Audience Analysis
Why have you been asked to design this training program?
To create the mistake less Process
What is their current level of knowledge on the subject of this program? What other similar programs have they attended in
Participants may aware few examples of Pokayoke (mistake Proffing). But this program focus Identifing the mistakes to arre
Paticipants may attends few quality or process improvements programs where they may aware the concept level.
What is likely to be their attitude towards the proposed training program? What is likely to be their motivation levels in attend
program?
Positive leraning attitute. Learning and implementation level
What should the learners know before attending this program?
Mistakes,defects,customer complaints,rework in their process
How many people need to go through this program?
Minimum batch of 25 members at a time
Where are they located?
Near training venue
What kind of learning experiences have they been through in the past? (basically to judge their ability to learn from various
OJT, CBT, WBT
Class room training and on the job experience
Is there an indicative duration that has been shared with you?
Yes.10 days before
Are there any other constraints that we need to know in designing this intervention? Can they be spared for x number of day
program? Is there a deadline by which the programs need to be completed? Are there travel constraints?
Its designed for 1 day program. classroom training
Is pre-work possible?
Identification of Mistakes,defects,customer complaints,rework in their process
Is post-work a possibility?
Yes. Project identification and pokeyoke implementation
How much can we count on the immediate managers to reinforce the learning?
Maximum
Task Analysis
What should the learners be able to do at the end of this training program?
At the end of the program learners can able to identfy the mistake opportunities and they solve the
Program name:
Audience Analysis
ase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)
of Age, Qualification, Experience?
ase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)(Upto 40 Years
nce)
monality between the learners?
which connecting (Supplier-Input-Process-Output-Customer)
ge differences (if any) among the learners?
knowledge on the subject of this program? What other similar programs have they attended in the past?
examples of Pokayoke (mistake Proffing). But this program focus Identifing the mistakes to arrest the mistake.
quality or process improvements programs where they may aware the concept level.
ude towards the proposed training program? What is likely to be their motivation levels in attending this
ences have they been through in the past? (basically to judge their ability to learn from various media) ILT,
he job experience
nts that we need to know in designing this intervention? Can they be spared for x number of days for the
by which the programs need to be completed? Are there travel constraints?
m. classroom training
d pokeyoke implementation
Task Analysis
Program Name:
Introduction
Created by:
1.2
2.1
2.2
Waste Management
3.1
3.2
3.3
4
4.1
4.2
5.1
5.2
6.1
6.2
6.3
6.4
6.5
6.5
7
7.1
7.2
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8.1
8.2
8.3
8.4
8.5
Summary
9.1
9.2
9.3
Created by:
Date:
Kaizen
Value
Waste
Elimination of Waste
Concept ZDQ
Benefits & How to achieve
Process Vs Quality defects
Human Mistakes
4 Components of ZDQ
Point of Origin Inspection
100% Audit checks
Immediate feedback
Pokayoke
Pokayoke
Guidelines to Pokayoke attainment
Contact Method
Counting Method
Revison
Methodology
(How the content will be delivered)
Content
( The content that needs to be covered if the
participant has to do the relevant EO)
Zero Defect
First time right & every time Right
Zero Rework
What is Kaizen
Time Vs Savings
Incremental improvements
Major Tools
Compasion of Kaizen , 6sigma& Lean
Rework
Scrap
Inspection Cost
Warranty Cost
1-10-100 Rule
what is Value?
Who defines Value?
Value in various business, process?
What is Non Value Added?
What are the wastes?
Wastes in various business,Process?
identification of wastes
Elimination of wastes
Zero is the GOAL
Process Control
ZDQ Makes Work Easier
Process Control
Relationship
What Causes Defects
What is Human Errors?
Types of Human Errors
Relationship between defects and Human Errors
How many Components in ZDQ
What are the compenets of ZDQ
3 Approaches of Inspection
Focus on Prevention
100% Inspection
assemptions
Importance of Feedback
Differs from traditional method
What is pokayoke
Explaination
Discussion
Examples
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Discussion
Discussion
Discussion
examples
Explaination
Explaination
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Importance
Quality Process
Utilize a team Environment
Elimination of Errors
Eliminate the Root Cause
Do it right the first time
Eliminate NVA
Implement Kaizen
Control Approach
Warning Approach
Contact
Counting
Motion-Sequence
Physical Contact
Energy Contact
Contact Devices
Contact Methods
Sensors
No of times
No of Parts
Concept
Sensors
Physical Contact
Touch Switch
Warning sensors
Energy Sensors
Dont Wait
Do it
Now
Problem discussion
Analysis the Root cause
Pokayoke development
Concept ZDQ
Human Errors
Poka yoke
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Methodology
ow the content will be delivered)
Time(Mins)
Logistics
(Special aids, arrangements to
be made)
To Understand
Partcipate in discusssion
Provide examples in their process
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Provide examples in their process
To Understand
To Understand
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
6
6
4
6
10
4
6
10
4
4
4
4
6
6
4
6
10
10
8
6
10
6
8
6
8
10
6
8
8
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
10
6
6
6
6
6
6
6
6
6
Projector
Screen
Speaker
White Board
4 colour Board Markers
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
8
8
6
8
8
8
Evaluation
Remarks/
Guidelines
(Books, manuals, website
references..)