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Poka-Yoke
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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.
QM&T's unique approach to this subjected has yielded huge
saving for organisations - see
post course assignments below |
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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.
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Books
Much more practical details regarding ZQC and Poka-Yoke are
provided in Vorley & Tickles book
Quality Management
(Tools & Techniques).
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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.
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| Identify where ZQC and Poka-Yoke can be used for best effect
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| 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 |
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.
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Morning
The ZQC course is broken down into:
| Phase I: Principles behind ZQC and Poka-Yoke
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| Phase II: Errors and mistakes
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| Phase III: Poka-Yoke function and devices
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| 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
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| Exercise associated with re-enforcing the morning s
Poka-Yoke theory |
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.
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If you would like
further information please contact
Edda Saunders 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 Information: Edda Saunders
sales@qmt.co.uk
Customer Support: Mary-Clare Bushell
tutor@qmt.co.uk |
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Links
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Our new Customer Satisfaction website which may help you
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Poka-Yoke:
http://www.poka-yoke.org.uk
Everything you wanted to know about Poke-Yoke and Fool or Mistake Proofing... |
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Security refers to the policies, procedures and technical measures used to
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well as a quality improvement technique. It began in the 1980’s at ... |
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Process Mapping:
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Process Mapping and Process Flow Charting are techniques that can be
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have the potential to identify significant savings in the way in which the
process is organised and performed. This is particularly so when aligned with
Process Cost Modelling... |
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Failure Mode Effects Analysis:
http://www.fmea-training.co.uk/
Failure Mode Effects Analysis (FMEA) or
to give it its correct title Failure Mode Effects & Criticality Analysis (FMECA)
is a logical technique used to identify and eliminate possible causes of
failure. |
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IQA Diploma:
http://www.iqa-diploma.co.uk
QM&T are an Institute of Quality Assurance (IQA) registered
Education Centre. This together with our team
having over fifty years experience of working with the IQA,
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Not getting the quality message across? New
starts and even existing employees seem unaware of the quality management
system or the importance of quality? |
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