Mistake-Proofing By Design Workshop

This in-house training describes the principles of mistake-proofing or poka-yoke and the evolutionary step of

addressing mistake-proofing during development versus installing mistake-proofing devices and

approaches on the factory floor after the product has been put into production. The workshop

includes many practical examples to illustrate the principles. The second day includes exercises to

develop mistake-proofing approaches with your current products and/or conducting a factory walk-

through to explore mistake-proofing opportunities.

1. INTRODUCTION

  • Why Mistake-Proofing – Defects Happen
  • Quality Framework and Evolution
    • Inspection to Detect Defects
    • Inspection to Provide Information to Improve the Process
    • Mistake-Proofing and Source Inspection to Eliminate Defects
  • Shiego Shingo: Source Inspection, Zero Quality Control, and the Poka-Yoke System
  • A Further Evolutionary Step – Mistake-Proofing By Design
  • The Six Principles of Mistake Proofing – an Introduction

2. MISTAKE-PROOFING PRINCIPLES

  • Hierarchy of Principles and Moving Upstream to Product & Process Design
  • Principle of Elimination
    • Role of Product Design – Design out Potential Defects
    • Examples
  • Principle of Replacement
    • Replace Error-Prone Product Features/Items
    • Replace Error-Prone Process Steps
    • Examples
  • Principle of Prevention
    • Prevent Errors with Product Design – Guidelines & Techniques
    • Prevent Errors with Process Design – Guidelines & Techniques
    • Poke-Yoke Devices – Sensors, Counters & Other
    • Examples
  • Principle of Facilitation
    • Product Design Techniques to Facilitate Error Avoidance
    • Process Design Techniques to Facilitate Error Avoidance
    • Visual Controls
    • Examples
  • Principle of Detection
    • Defect Detection – Poke Yoke Devices & Self-Checking
    • Examples
  • Principle of Mitigation

3. POKA YOKE

  • The Three Primary Poka Yoke Methods
    • Contact
    • Counting
    • Motion-Sequence
  • Types of Sensing Devices
  • Poka Yoke Applications and Examples
  • Poka Yoke in Automated vs. Manual Processes

4. MISTAKE-PROOFING AND DFM/A

  • Principles of Design for Manufacturability/Assembly (DFM/A)
    • Avoiding Complexity – Simplicity and Standardization
    • Part Orientation and Handling to Facilitate Mistake-Proofing
    • Insertion and Assembly
    • Fastening
  • Tolerances and Process Capability
  • Impact of DFM/A on Quality and Defects
  • DFM/A Examples
  • Relationship of DFM/A Principles to Mistake-Proofing
  • DFM/A and Mistake-Proofing Exercises

5. MISTAKE-PROOFING USE AND SERVICE

  • Mistake-Proofing Customer Use
  • Mistake-Proofing Customer Use Examples
  • Mistake-Proofing Product Service
  • Mistake-Proofing Service Examples

6. PROCESS FOR MISTAKE-PROOFING BY DESIGN

  • Three Approaches to Mistake-Proofing
    • Defect Analysis (Existing Products)
    • Prioritizing Opportunities with Failure Modes and Effects Analysis
    • Comprehensive Process Step Design
  • Mistake-Proofing Taxonomy
  • Understanding and Applying the Economics of Mistake-Proofing
  • Examples of Mistake-Proofing with Your Products
  • Discussion of Potential Opportunities with Your Products

7. SUMMARY

  • Steps to Take to Implement a Mistake-Proofing Program
  • Discussion and Questions

8. PRODUCT ANALYSIS OR FACTORY WALK-THROUGH

  • Workshop Exercise to Apply Principles and Analysis to a Current Product
  • Factory Walk-Through to Identify Mistake-Proofing Opportunities and Techniques