The Poka-Yoke error prevention course
INTRODUCTION
Poka-Yoke is fool proofing, which is the basis of the Zero Quality Control (ZQC) approach, which is a technique for avoiding and eliminating mistakes. Generally this technique is used in manufacturing process but has much wider uses, such as; offices - order and invoice processing, hospitals - drug dispensing, aircraft maintenance - particularly with processes having the potential of inducing catastrophic in-service failures. The term Poka-Yoke is Japanese and can roughly be translated as mistake or fool proofing. It is derived from ‘Poka’ - inadvertent mistake and ‘yoke’ - avoid. Of course, the concept of fool proofing processes and mechanical devises has been around for many years (e.g. see photographs of floppy disk drive and electrical plugs) but is was the Japanese Matsushita Industrial Engineer Dr. Shigeo Shingo who was probably most prominent and influential in developing it into a technique. He turned the idea into a powerful approach for eliminating mistakes and achieving zero defects. Dr. Shingo used the phrase "error avoidance", as he recognised that people, or more specifically Japanese workers, may take offence at the term fool, particularly when associated with mistakes. This is especially important when considering the technique and approach requires the workers active participation in the error cause removal programme. Note, error cause removal and zero defects are phases first used by Philip Crosby but the approach is very different and should not be confused.
Dr. Shingo wrote the book "Zero Quality Control: Source Inspection and the Poka-yoke system" in 1986. This original source material defined the basic approach. However, the technique has been extensively developed since. Dr. Shingo also suggests that statistical process Poka-Yoke is fool proofing, which is the basis of the Zero Quality Control (ZQC) approach, which is a technique for avoiding and eliminating mistakes. Generally this technique is used in manufacturing process but has much wider uses, such as; offices - order and invoice processing, hospitals - drug dispensing, aircraft maintenance - particularly with processes having the potential of inducing catastrophic in-service failures. The term Poka-Yoke is Japanese and can roughly be translated as mistake or fool proofing. It is derived from ‘Poka’ - inadvertent mistake and ‘yoke’ - avoid. Of course, the concept of fool proofing processes and mechanical devises has been around for many years (e.g. see photographs of floppy disk drive and electrical plugs) but is was the Japanese Matsushita Industrial Engineer Dr. Shigeo Shingo who was probably most prominent and influential in developing it into a technique.
Much more practical details regarding ZQC and Poka-Yoke is provided in Vorley & Tickle's book Quality Management (Tools & Techniques).
Free copy of the book Quality Management by Geoff Vorley & Fred Tickle provided for each course delegate.
Business Benefits
To enable delegates to:
- Understand and implement the “Poka-Yoke" methodology
- Understand and practically employ the basic techniques associated with Zero Quality Control (ZQC) and Poka-Yoke.
- Identify where ZQC and Poka-Yoke can be used for best effect
- Coordinate and motive the Poka-Yoke team to provide real, tangible solutions to what appear to be intractable quality problems.
- Train others in the ZQC and Poka-Yoke methodology
- Provides the opportunity to make real major financial saving through QM&T's pre and post course supported assignment scheme.
- Be QM&T validated and certificated Poka Yoke practitioner.
Who Should Attend?
Quality, Engineers, Software, Food & Drug, etc. professionals who wish apply the ZQC model and methodology to error prevention and problem solving together with obtaining a clear knowledge of ZQC associated techniques.
Course Structure
Morning
The ZQC course is broken down into:
- Phase I: Principles behind ZQC and Poka-Yoke
- Phase II: Errors and mistakes
- Phase III: Poka-Yoke function and devices
- Phase IV: ZQC implementation
Together with presenting practice examples of Poka-Yoke techniques, devices and case studies
Afternoon
- Practical Case Studies associated with ZQC and Poka-Yoke
- Exercise associated with re-enforcing the morning s Poka-Yoke theory
Course dates and cost
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