Poka-Yoke

Poka-Yoke

Human Error

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 technique is often seen as part of an organisations; Lean, Value Stream Analysis, Root Cause Analysis programme.

QM&T's unique approach to this subjected has yielded huge saving for organisations - see post course assignments below

Example 1

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.

Example 2

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.

Tools & Techniques - D3

Books

Much more practical details regarding ZQC and Poka-Yoke are provided in Vorley & Tickles book Quality Management (Tools & Techniques).

Poka-Yoke Training Courses

Business Benefits

To enable delegates to:

bulletUnderstand and implement the Poka-Yoke methodology
bulletUnderstand and practically employ the basic techniques associated with Zero Quality Control (ZQC) and Poka-Yoke.
bulletIdentify where ZQC and Poka-Yoke can be used for best effect
bulletCoordinate and motive the Poka-Yoke team to provide real, tangible solutions to what appear to be intractable quality problems.
bulletTrain others in the ZQC and Poka-Yoke methodology

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:

bulletPhase I: Principles behind ZQC and Poka-Yoke
bulletPhase II: Errors and mistakes
bulletPhase III: Poka-Yoke function and devices
bulletPhase IV: ZQC implementation

Together with presenting practice examples of Poka-Yoke techniques, devices and case studies

Afternoon

bulletPractical Case Studies associated with ZQC and Poka-Yoke
bulletExercise associated with re-enforcing the morning s Poka-Yoke theory
Post Course Assignment & Support

Following the course the delegates are encouraged to complete an Poka-Yoke work based assignment.  Successful completion of this assignment is necessary for the delegates to receive their QM&T Poka-Yoke practitioner certificate.  Throughout this period (typically one month) email support is provided from a QM&T recognised Poka-Yoke professional.

Case study material available on request.

   

Contact Information

If you would like further information please contact Sales at:

 

Telephone:    +44 -0 1483 453511
Fax:    +44 -0 1483 453512
Postal address:   Quality Management & Training Limited PO Box 172, Guildford, Surrey, GU2 7FN United Kingdom
Electronic mail:
Technical Support: help@qmt.co.uk
General Informationsales@qmt.co.uk
Customer Support:  tutor@qmt.co.uk
 
 

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© Quality Management & Training Limited    Thursday, 07 July 2011

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