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.
This workshop is conducted onsite for individual clients and customized to the client’s products and production processes using client examples to illustrate the mistake proofing principles. The workshop will involve working sessions to identify opportunities to incorporate mistake-proofing in the product’s design and in the production process design.
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 ORIGINAL FOCUS ON MISTAKE-PROOFING PRODUCTION
- 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
- Mistake-Proof the Product Design as Well as the Production Process
- 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
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
- Mistake-Proof Insertion and Assembly
- Mistake-Proof 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