Poka Yoke – Your Ultimate Tool For Zero Mistakes And Zero Errors

26-27 Jul, 2018, Kuala Lumpur

FOCUSING ON
  • Why Poka Yoke?
  • Introduction to Poka Yoke
  • Poka Yoke Approach
  • Eliminate Human Induced Mistakes
  • Prevent Unexpected Equipment Errors
  • Make Systems Fool-Proof Always
  • Evaluate Poka Yoke Solutions
OVERVIEW

Mistakes and errors are becoming the talk of every day when some thing goes wrong. In industries, this elevates to high level as the number of people and number of machines are in large number. Most of the times when mistakes and errors happened, the training and awareness levels are blamed and immediate attention given to training and awareness. However, this two only last for a few weeks and the scenario returns back.

 

In reality, training and awareness cannot eliminate mistakes and errors. This are just temporary actions that will contain problems from spreading. Training and awareness building are just like tonic drink “livita” and will last only for a short period. Therefore, hoping on this two will never solve the issue of mistakes and errors.

 

In 1963, a Japanese statistical engineer by the name of Mr. Shigeo Shingo, proved that :

people will make mistakes
people can make mistakes
mistakes and errors are un-avoidable

 

In his study, he found, in-order to eliminate mistakes and errors, one should look for the potential that caused the mistake or error. By eliminating the potential, we can prevent mistakes and errors from making. Every mistake or error has one or many potentials that are waiting to happen. As long as this are not eliminated, the mistakes and errors are doomed to happen.

 

Mr. Shigeo Shingo devised a method to eliminate the potential which he named as ‘poka yoke’ that translates to “eliminate unintentional mistakes”. This concept spread worldwide as a formidable tool for eliminating mistakes and errors. Poka Yoke becoming a well known mistake proofing tool in all manufacturing industries.

OBJECTIVE

This course will show participants :

  1. Why people make mistakes
  2. Why errors happen in machine operation
  3. How to find out the potential that lead to making mistakes
  4. How to establish the objectives of poka yoke
  5. How to select the techniques
  6. How to apply the detection tools
  7. How to use the poka yoke flow chart
BENEFITS OF ATTENDING THE COURSE…

Participants will know and understand :

  1. How to determine the potential.
  2. How to select the objective.
  3. How to determine the technique.
  4. How to apply the detection methods.
  5. Practically apply the poka yoke flow chart.
WHO SHOULD ATTEND
  • All Managers
  • Engineers
  • Supervisors
  • Technicians of Manufacturing group
METHODOLOGY
  • Interactive Lectures
  • Explanations
  • Case Studies
  • Group Discussions
  • Q & A Sessions
DAY 1
9:00 MODULE 1 – WHY POKA YOKE?
  • Errors and mistakes destined or created
  • Common people mistakes
  • Common equipment errors
  • Common design short comings
  • Can all errors and mistakes eliminated – activity
10:45 MODULE 2 – INTRODUCTION TO POKA YOKE
  • Definition of Poka Yoke
  • History of Poka Yoke
  • Concept of Poka Yoke
1:00 Lunch

2:00

MODULE 3 – POKA YOKE APPROACH

  • Determine the purpose
  • Establish the technique
  • Select the detection tool
  • Poka Yoke flow chart
3:45 MODULE 4 – ELIMINATE HUMAN INDUCED MISTAKES
  • Why humans make mistakes
  • Understanding the root cause
  • Determine the purpose
5:00 End of Day 1
DAY 2
9:00 MODULE 4 – ELIMINATE HUMAN INDUCED MISTAKES (cont.)
  • Techniques for eliminating human mistakes :
    Technique 1 : guide pin/block method
    Technique 2 : asymmetry principle
    Technique 3 : counters
    Techniques 4 : color codes
    Technique 5 : checklists
10:45 MODULE 5 – PREVENT UNEXPECTED EQUIPMENT ERRORS
  • Why errors occur in equipments
  • Understand the weaknesses
  • Determine the purpose
  • Techniques for eliminating equipment errors :
    Technique 6 : contact methods
    Technique 7 : contact-less methods
    Technique 8 : condition monitor methods
    Techniques 9 : operational changes
    Technique 10 : environment changes
    Technique 11 : error detection programs
1:00 Lunch

2:00 MODULE 6 – MAKE SYSTEMS FOOL- PROOF ALWAYS
  • Common system errors
  • Understanding the root causes
  • Techniques for eliminating system errors :
    Technique 12 : asymmetry methods (shape)
    Technique 13 : go-no go methods (fitting)
    Technique 14 : electronic control methods
    Techniques 15 : early warning methods
    Technique 16 : immediate shut down methods
3:45 MODULE 7 – EVALUATE POKA YOKE SOLUTIONS
  • Negative box-paradigm
  • Common mental blocks
  • Idea generation for Poka Yoke
  • Guidelines for idea selection
  • Golden rule of Poka Yoke – keep it simple
5:00 End of Course

 

LEARN FROM THE BEST

Mr. P. Balachandran brings to this course more than 17 years of solid industrial experience in the manufacturing sector as well as 12 years in maintenance manufacturing training and consultancy.

 

His experience includes that of Equipment Engineer, Section Head of Production, Production Manager and Training & Education Manager with well known corporations such as Motorola, Thomson Audio Electronics and Samsung Electron Devices.

 

Mr. Bala then became involved in management consultancy and trained full time in specific areas of manufacturing and maintenance training. His natural leadership style coupled with his vast industrial experience makes a valuable partner and resource in developing the workforce of the manufacturing sector and in trouble shooting.

 

Mr. Bala has trained more than 3000 professionals
and some of the companies that have benefited
from his expertise include Komag Malaysia, Minolta, Silitek, Sony Malaysia, Robert Bosch, TDK Malaysia, Swedish Motor Assembly, Western Digital, Dell Computers, Texas Instruments, TNB, Genting Sanyen, PROTON, Teck See Plastics, Hicom, Philips Semiconductor, Airod, B Braun, Carsem, Dynacraft, Seagate Industries, Mattel, Perodua, Johnson & Johnson and Malaysian Airlines System.

 

VENUE DETAILS

Furama Hotel Kuala Lumpur
136, Jalan Changkat Thambi Dollah
55100 Kuala Lumpur

Phone :03-2788 8888

 

IPA TRAINING IS REGISTERED WITH

 

CONTACT US

Juliany, 
O - 03 2283 6109,
M - 019 3134436
juliany@ipa.com.my 

Michelle, 
O - 03 2283 6100, 
M - 019 363 7822
michelle@ipa.com.my 

For Customised In-House Training
Yvonne,
O - 03 2283 6101, 
M - 012 2011247,

F - 03 2283 6108
 
yvonne@ipa.com.my
 

ADDRESS 

A-28-5, 28th Floor, 
Menara UOA Bangsar, 
No.5, Jalan Bangsar Utama 1, 
59000 Kuala Lumpur
www.ipa.com.my