Poka Yoke Workshop/Training -Mistake Proofing Towards Zero Defects (Online Training)

Course Objectives

Poka Yoke is a Japanese term literally defined as ‘mistake proofing’. Poka-Yoke is often used in the context of designing devices, typically simple and inexpensive, that prevent defects from being made or, if they are made, from moving to the next process.

.Participants will learn to:

  • Understand the principles of Poka Yoke
  • Understand and employ the basic techniques with Poka Yoke
  • Identify where Poka Yoke can be used for best effect
  • Be able to implement Poka Yoke

Target Audience

Company personnel (process engineers, production engineers, QA engineers) who are responsible in managing and support development of poka yoke mechanisms  in a systematic and effective manner.


This Live Online / Virtual Training session will be conducted via a Live Streaming Platform in which the trainer will use interactive lecture and slide presentation to cover the modules stated below.

Course Modules

  • Module 1 – Introduction to Poka Yoke Technique
    – Tribute to Shigeo Shinge
    – Not punishing workers for mistakes
    – Initial term
    – Defects cannot be totally prevented
    – Defects can be prevented by
    – What is poka yoke ?
    – Other Mistake-proofing Devices
    – Everyday Examples
    – What are the benefits
    – Why do poka yoke?
  • Module 2 – Scope of Poka Yoke Application
    – 4M factors
    – Different inspection methods
    – Judgement inspection
    – Informative Inspection
    – Successive Check System
    – Self check system
    – Source Inspection
    – Prevention methods
  • Module 3 – Regulative Function
    – Warning method
    – Control method
    – Non-engineering application
  • Module 4 – Setting Function
    Contact method
    – Physical Contact Devices
    – Energy Contact Devices
    – Contact Device
    – Various type of contact detection devices
    – Various type of non-contact detection devices
    – Contact method examples
    Constant Value Method/Counting Method
    – Counting method examples
    – Constant value method examples
    Motion step method
    – Motion-Step Method examples
    – Types of Sensing Devices
  • Module 5 – Implementation Of Poka Yoke System
    – Implementation steps
    – Steps to error proofing
  • Module 6 – Poka Yoke Consideration In Service Industry
    – Physical detection and control, Sequencing, Grouping and counting, Information enhancement
    – Task Errors, Treatment Errors, Tangible Errors,Preparation Errors, Encounter Errors, Resolution Errors
  • Module 7 – JIDOKA
    – Technical Elements of TPS
    – Focus on Jidoka
    – What is Jidoka?
    – What does Jidoka do?
    – How Your Organization Can Benefit From Jidoka
    – A Closer Look at Jidoka
    – Perfection and Jidoka
    – Jidoka example

Get To Know The Trainer

Trainer Tejwinder


Tej is one of the pioneers in quality system management development in Malaysia. Tej has been involved in quality management consulting and training for the past twenty five years. His last position was the Managing Consultant of a UK based international consulting firm’s Regional Office in Kuala Lumpur. Tej has trained over 50,000 personnel worldwide.

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RRP RM2,000/DAY   SAVE RM550

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