Lean Mistake Proofing (Poka-Yoke) Training

Course Duration: 2 Days - 8 Hours/day

This two-day workshop offers instruction and practice in application of the tools and methodologies used in striving for perfection. This workshop provides instruction and guided practice in the application of Mistake Proofing devices to equipment downtime. Participants will determine the cost savings and increased productive capacity resulting from Mistake Proofing.

Learning Objectives

  • Understand the philosophy, history, and benefits of Mistake Proofing
  • Understand how Mistake Proofing fits into a modern quality management system
  • Develop your ability to plan and deploy Mistake Proofing methods to achieve significant reductions in defect rates

Course Outline

  • History of Mistake Proofing
  • Relationship between Operating Conditions, Mistakes, and Defects
  • Mistake Proofing and APQP Process
  • Prevention versus Detection Systems
  • Mistake Proofing Development Process
  • Mistake Proofing Toolbox
  • Creative and Structured Problem Solving
  • Evaluating Mistake Proofing Systems
  • Closing the Loop – Mistake Proofing and APQP
  • Performance Management and Mistake Proofing

Who Should Attend

This workshop is designed for those responsible for improving quality and productivity in manufacturing operations. This workshop is an applied workshop. Participants will apply the lessons learned to real world plant equipment. This workshop is team-based. Each team should include the Process Champion and up to four Lean Sense is. There is a limit of 3 teams per session.

Course Materials

Each participant will receive a workshop manual and a workbook including workshop exercises.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.


Ideally participants will have developed current and future state maps for the process selected for improvement.

Upcoming Training