Poka-Yoke Workshop - Eliminating Defects Caused by Human Error
(GBMP members get one free seat; groups of five or more only $99 each: Email Lglikes@gbmp.org to get your coupon code. Need an invoice? Email Lglikes@gbmp.org for assistance.)
Meets on October 26, 2023, from 8AM to 12 Noon EST
Poka-yoke, or mistake-proofing, is one of the most powerful concepts of Lean, yet after many years in the public eye, it is still one of the least practiced. Why? This course will explore answers to this question as well as the dangerous counter-effects of traditional responses to defects and how our legacy quality and management systems propagate the status quo. Broad implementation of poka-yoke devices can reduce defects caused by human errors absolutely to zero! Dr. Shigeo Shingo, an industrial engineer at Toyota, borrowed the concept from military “fail-safing” by identifying the exact time and place where inadvertent errors occurred and then placing a protective device to prevent the error from occurring. To be a poka-yoke device, Shingo suggested, it would need to meet three critical criteria. Learn the critical criteria for creating a successful poka-yoke device as developed by Dr. Shingo.
The workshop will also introduce prevent and detect type poka-yoke devices. Prevent-type devices are the goal but detect-type devices are a close second. Learn how Shigeo Shingo used detect-type poka-yoke devices strategically to create the desired prevent-type poka-yoke devices. Several examples of each type will be provided. Finally, learn why understanding poka-yoke in the context of strategy and organization is a key to creating a company-wide poka-yoke system.