Course Overview

How can we make errors, defects and mistakes either so 'visible' that we can detect them at source or even better eliminate them altogether?

The answer is by applying Poka Yoke techniques.

Poka Yoke is the lean manufacturing tool which forms the basis of the Zero Quality Control (ZQC) system for avoiding and eliminating mistakes, defects and errors. The term Poka Yoke is derived from the Japanese words ‘Poka’ meaning inadvertent mistake and ‘yokeru’ – meaning to avoid.

This one day practical training course is delivered in a fun, innovative manner with the delegates being required to assemble \'real\' products as part of the course. By application of the theory from the course, delegates can see first hand how an array of mistake–proofing techniques and devices can virtually eliminate the opportunity for errors before they become defects. A truly inspirational experience.

This course is suitable for all production operators, supervisors, managers, continuous improvement engineers, quality engineers and production engineers.

What you will learn

At the conclusion of the course each delegate will be able to:-

• Differentiate between judgement, informative and source inspection
• Understand the benefits of source inspection
• Decide where to implement Poka Yoke methodology in their own environment
• Understand the difference between mistakes, errors and defects
• Understand the different types of errors and how to address them
• Understand the different types of defects and how to address them
• Predict where errors and defects are likely to occur
• Be able to design and implement a Poka Yoke programme
• Use a number of tips & techniques to get the buy-in of their team
  

Course Content

The Poka Yoke training course covers the following topics:-

• Poka Yoke, Zero Quality Control – Definitions
• The distinctions between judgment inspection, informative inspection and source inspection
• What is a Poka Yoke System ?
• The Poka Yoke Method
• Predicting where Poka Yokes are needed
• How to prevent errors from occurring
• How to detect abnormalities as they occur
• How to control or shutdown a process producing defects
• Examples of everyday Poka Yoke including real examples for tackling mistakes arising from the following type of operations:-
• Assembly, Insertion, Inspection, Locating, Mounting, Omissions, Processing and Set Up
• Poka Yoke Improvement Forms
• How to use team work to Implement the changes
• Course Review

This course uses practical demonstrations to re-enforce the theory.

Courses are limited to a maximum of twelve delegates. Course costs cover the training sessions, a comprehensive set of course notes and an attendance certificate.

Costs are exclusive of VAT which is chargeable at the current rate. Prices are correct at the time of publishing, but may be varied in line with market conditions from time to time.

This course can also be delivered on your site if required.