Mistake-Proofing by Design Workshop

This two-day workshop describes the principles of mistake-proofing or poka-yoke and the proactive approach 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.

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. 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

3. 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
    • Examples

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 Process 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 and Production Process
  • Factory Walk-Through to Identify Mistake-Proofing Opportunities and Techniques