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American Express
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File Size: 38.4 MB


Number of Slides: 121


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Training Presentation/PowerPoint:

Mistake-Proofing (Poka-Yoke)

The Effective Approach to Zero Defects


The Zero Quality Control (ZQC) is the most effective mistake-proofing approach. The system prevents defects as well as monitors processing conditions at the source and corrects errors that would cause defects.

Based on the breakthrough approach developed by Dr. Shigeo Shingo, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. Poka-yoke is a technique used to prevent mistakes from occurring in a process. It involves designing a process in such a way that it is impossible to make mistakes.

This Mistake-Proofing PPT training presentation introduces the basic methodology of ZQC in a logical format and covers all aspects of this important manufacturing improvement strategy. You will learn that the culture of zero defects can be developed by training and educating teams on the approaches to poka-yoke, and using contact and non-contact methods with visual controls and auditory systems to create effective, reliable and low-cost poka-yoke systems that catch mistakes and prevent defects from happening.

Note: This training package includes:

1. Mistake-Proofing PPT training presentation (PowerPoint format, 16:9 widescreen)

2. The Inspection Exercise (PowerPoint format, 4:3 standard screen)

Learning Objectives


  1. Acquire knowledge on the key concepts and principles of Zero Quality Control

  2. Learn the approaches, methods and tools for designing and implementing poka-yoke systems

  3. Identify the limitations and best practices of mistake-proofing


1. Introduction to Zero Quality Control

  • Introduction to Mistake-Proofing

  • Traditional Inspection is a Poor Substitute for Quality
  • Towards a Culture of Zero Defects
  • Error Prevention is Better than Defect Detection
  • The 1-10-100 Rule
  • Poor Quality Costs a Typical Company 15-20% of Sales Annually
  • Statistical Quality Control vs. Zero Quality Control
  • Quality Levels & Improvement Approaches
  • What is Zero Quality Control?
  • Mistake-proof is the Apex of Quality
  • ZQC is the Mistake-proofing Approach to Zero Defects
  • Why Focus on Zero Defects?
  • How ZQC Makes Your Work Easier
  • What Causes Defects?
  • Goal of ZQC
  • The Traditional Quality Improvement Cycle
  • Integrating Do & Check is the ZQC Approach


2. Basic Elements of the ZQC System

  • The Four Elements of ZQC

  • Source Inspection

  • Three Approaches to Product Inspection and their Results

  • Judgment Inspections Discover Defects

  • Informative Inspections Reduce Defects

  • Statistical Quality Control (SQC)

  • Successive Checks

  • Self-Checks

  • Source Inspections Prevent Defects

  • 100 Percent Inspection Catches All Errors

  • A Short Feedback Loop Means Quicker Action on Problems

  • Poka-yoke Catch Errors We Might Have Missed


3. Using Poka-yoke Systems

  • What is Poka-yoke?

  • What Poka-yoke Is Not

  • Poka-yoke and Jidoka

  • Everyday Examples of Poka-yoke

  • Common Errors in Operations and Assembly

  • Requirements of a Good Poka-yoke System

  • Two Approaches to Poka-yoke

  • Dual Focus of Poka-yoke Systems

  • Poka-yoke Systems in Source Inspections

  • Poka-yoke Systems in Informative Inspections

  • How Poka-yoke Systems Regulate the Process

  • Contact Methods

  • Fixed-value Methods

  • Motion-step Methods

  • Types of Sensing Devices

  • Warning Sensors

  • Devices that Link to Poka-yoke Sensors


4. Examples of Poka-yoke Applications

  • Safety Cover

  • Go / No Go

  • Dispensing Equipment

  • Space Separation

  • Kitting

  • Pick-to-Light

  • Rhythmic Movement

  • Highlight

  • Time Separation

  • Traffic Flow

  • Trend Prediction

  • Eliminate Replacement Alternative (ERA)

  • Checklists

  • 5S Workplace Organization

  • Tool Board/Drawer

  • Drive Tension Guides

  • Pharmacy

  • Medical Records

  • Alternative Use of Resources

  • Rejects or Materials Hold for QA

  • Three Rules of Poka-yoke


5. Limitations & Best Practices

  • Limitations of Poka-yoke and the ZQC System

  • Best Practices


You may also be interested in the following training presentations (sold separately):

  1. A3 Problem Solving Process & Tools

  2. 8D Problem Solving Process & Tools

  3. PDCA Problem Solving Process & Tools

  4. 5 Steps of Problem Solving

  5. Business Process Reengineering (BPR)

  6. Problem Solving & Visualization Tools

  7. Advanced Product Quality Planning (APQP)

  8. Failure Mode & Effects Analysis (FMEA)

  9. Mistake-Proofing

  10. Total Quality Management

  11. Root Cause Analysis

  12. Reducing the Cost of Quality


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