Mistake Proofing

Training - Poka Yoke

Call Us Today: +1-972-665-9786

https://www.tonex.com/training-courses/mistake-proofing-training/

Since 1993, Tonex has specialized in providing industry-leading training, courses, seminars,
workshops, and consulting services. Fortune 500 companies certified.
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Since 1993, Tonex has specialized in providing industry-leading training,
courses, seminars, workshops, and consulting services.

Why Tonex ?

--Presenting highly customized learning solutions is what we do. For over 30

years TONEX has worked with organizations in improving their
understanding and capabilities in topics often with new development,
design, optimization, regulations and compliances that, frankly, can be
difficult to comprehend.

--Ratings tabulated from student feedback post-course evaluations show an

amazing 98 percent satisfaction score.

--Reasonably priced classes taught by the best trainers is the reason all kinds
of organizations from Fortune 500 companies to government’s most
important agencies return for updates in courses and hands-on workshops
Audience:
2-day course designed for:

• Executers and decision makers of the organization

• Leaders
• Managers and supervisors
• Engineers
• jjij
• Process improvement managers and leaders
• System implementers and coordinators

Price: $1,699.00 Length: 2 Days

Mistake Proofing Training - Poka Yoke TAKE THIS COURSE

https://www.tonex.com/training-courses/mistake-proofing-training/
Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
https://www.tonex.com/training-courses/mistake-proofing-training/
 Mistake proofing training, or Poka Yoke, course
acquaints you with the essentials, process,
methods, and gadgets important to wipe out
mistakes, before they happen. The least difficult,
quickest, and best approach to dispose of
mistakes is to modify the pathways that lead us to
make them. For example, the less advances
workers need to memorize to carry out their
activity the less mistakes they can make.
Therefore, mistake-proofing arrangements
incorporate numerous tedious errands with the
procedure itself. When individuals' psyches are
free and they are not under the worry of
recollecting errands, they have room schedule-
wise and the shot of being innovative and more
productive. Mistake proofing training course will
enable you to grow such arrangements in view of
your business.

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Students also will learn about four different approaches to change a process to eliminate mistakes:

• Prevention method
• Detection method
• Fail-safely method
• Work environment

Moreover, through mistake proofing training course, you will learn how to change the mindset of
your organization. Change must start from the leaders and those who establish the process. Leaders
must conceive the belief that mistakes are not welcome or acceptable in the organization. They are
the ones who must establish mistake-proofing mindset among the employees.

The mistake proofing training course will help you implement such system, get the decision makers
on board, and educate your team to get comfortable with the process.

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https://www.tonex.com/training-courses/mistake-proofing-training/
Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
https://www.tonex.com/training-courses/mistake-proofing-training/
 Training Objectives

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• Understand the goal and importance of mistake proofing
• Identify the mistake-proofing solutions in the daily life
• Apply mistake proofing methods and techniques in their work to reach the zero defects process
quality
• Recognize the input elements of each process
• Identify the source of mistakes
• Use practical approaches to cut off the non-quality cost
• Implement the mistake proofing Seven Criteria
• Use the Five Mistake-Proofing Imperatives
• Choose the best mistake-proofing devise by using the Ten Point Scoring Technique
• Recognize the forced control effect
• Identify some of the types of the shutdown effect sensors
• Apply sensory alert effects
• Find the root cause
• Apply proper mistake proofing solution in each root cause
• Evaluate and assess the applied solution in regards to its effectiveness, feasibility, and cost
• Avoid overriding he solution by building it in the process
• Check how much your solution is robust

Mistake Proofing Training - Poka Yoke TAKE THIS COURSE

https://www.tonex.com/training-courses/mistake-proofing-training/
Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
https://www.tonex.com/training-courses/mistake-proofing-training/
 Course Outline

Mistake Proofing Training - Poka Yoke TAKE THIS COURSE

https://www.tonex.com/training-courses/mistake-proofing-training/
• Overview To Mistake-Proofing
• Introduction to Poka Yoke
• Daily Life Mistake-Proofing Solutions
• Defects And Costs
• Reasons Behind Mistakes
• Zero Defect Quality System (ZDQ)
• Principals Of Mistake-Proofing
• Mistake-Proofing Process
• Root Cause Analysis Tools for Mistake-Proofing
• General Failure Modes
• Inspection vs. Mistake-Proofing
• What You Need To Know To Start Mistake-Proofing?
• Mistake-Proofing Tactics
• Mistake-Proofing Devices
• Mistake-Proofing Solutions
• The TRIZ Approach

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Overview To Mistake-Proofing

• What is mistake proofing or Poka Yoka?

• How to find the source of mistakes?
• How to set a mistake-proofing mindset among your organization?
• Zero Quality Control (ZQC)

Introduction to Poka Yoke

• Basic functions of Poka Yoke

• Poka Yoke culture
• Positive and negative cultures

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 Poka Yoke
Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
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Daily Life Mistake-Proofing Solutions

• Find examples of mistake-proofing around you

• How to get ideas from them at work

Defects And Costs

• Importance of ZQC
• Costs of defects
• Re- and extra work
• Scrap
• Warranty costs
• Inspection costs
• The 1-10-100 rule

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Reasons Behind Mistakes

• You harvest what you planted

• Importance of identifying root causes of mistakes
• Common mistakes causing defects
• Common defect categories

Zero Defect Quality System (ZDQ)

• Definition and concept

• How ZDQ makes your work easier?
• How to achieve ZDQ?
• Components of ZDQ
• Inspection
• Audit checks
• Immediate feedback
• Poka Yoke

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Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
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Principals Of Mistake-Proofing

• Preventing mistakes
• Elimination
• Replacement
• Facilitation
• Minimizing the effects of mistakes after they are made
• Detection
• Mitigation

Root Cause Analysis Tools for Mistake-Proofing

• The 5-whys
• What is and what isn’t a problem
• Data collection and display
• Failure analysis
• Simulations
• Statistical analysis
• Check the root cause back

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Mistake-Proofing Process

• Process overview
• Quality process
• Team environment
• Eliminate errors
• Do it right the first time
• Eliminate excuses
• Implement improvement actions
• FEMA analysis
• Root Cause Analysis
• Develop and implement mistake-proofing solutions
• Control Plan

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Mistake Proofing Training - Poka Yoke TAKE THIS COURSE
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General Failure Modes

• Process failure
• Omission
• Excessive repetition
• Wrong sequence
• Early/late execution
• Selection failure
• Incorrect identification
• Incorrect calculation
• Perception failure
• Overlooking
• Misreading/Misunderstanding
• Incorrect decision
• Miscommunication
• Motion Failures
• Other Failures

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Inspection vs. Mistake-Proofing

• Concepts and backgrounds on inspection

• Inspection’s limitations
• “Self-check” inspection
• “Successive-check” inspection
• Prevention always better than detection

What You Need To Know To Start Mistake-Proofing?

• The language of mistake-proofing

• The role of each team member in the mistake-proofing process

Mistake-Proofing Tactics

• The 8 types of mistake-proofing solutions

• How to select the approach suitable for you?

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Mistake-Proofing Devices
• Forced control devices
• Shutdown devices
• Warning devices
• Sensory alert devices

Mistake-Proofing Solutions
• Include mistake-proofing solutions into problem-solving procedures
• Evaluate your solutions in regards to their viability and cost-effectiveness
• How to avoid overriding your solutions
• Evaluate the robustness of your solutions
• How to complement your solutions

The TRIZ Approach

• Trimming
• Self elimination
• Standardizing , Copying
• Pre-action, Color
• Combining, Counting & Automation

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 Mistake Proofing
Training – Poka Yoke

Call Us Today: +1-972-665-9786

https://www.tonex.com/training-courses/mistake-proofing-training/

TAKE THIS COURSE

Contact Tonex Training Expert
Dallas, TX:

1400 Preston Rd., Suite 400

Plano, Texas 75093
Tel: +1-972-665-9786

Washington, DC:

1025 Connecticut Ave, NW Suite 1000

Washington, DC 20036
Tel: +1-202-327-5404

International: +1-214-762-6673
Fax: +1-972-692-7492

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