Course sheet · 2027 catalogueOperational excellence
Poka-Yoke and Error-Proofing
One day to design error-proofing devices that prevent the mistake instead of relying on the operator's attention. Participants analyse the human errors behind defects at your site, choose the right type of device, from a jig to a sensor, and organise its regular verification. The workshop takes place on a real workstation and produces simple solutions that your maintenance team can build.
Duration1 day
Request a quoteObjectives
- Explain the difference between an error and a defect, and why human inspection is not enough to stop defects
- Identify the recurring errors of a workstation: omission, inversion, wrong part, wrong setting, skipped step
- Choose a contact, fixed-value or motion-step device, with a shutdown or alert function
- Design simple solutions with the operators, methods and maintenance
- Set up periodic verification of the devices and the reaction in case of failure
Programme
Day 1 — morning
- Human error and defect: origins, typology, limits of visual inspection
- Principles of poka-yoke: preventing the error, or detecting it before it becomes a defect
- Detection methods: contact, fixed value, motion step; shutdown, blocking or alert functions
- Examples in assembly, packing, labelling and machine loading
Day 1 — afternoon (workshop)
- Choosing workstations: complaints, scrap, process FMEA, special characteristics
- Workshop: on a real workstation at your site, analysis of possible errors and sketching of devices
- Verifying devices: good and bad reference parts, frequency, recording, reaction
- Integration into the workstation standard and the control plan
- Knowledge test and presentation of the solutions to supervisors
Teaching methods
- Observation of a real workstation with the operators who work there
- Group search for solutions with production, maintenance and methods
- A bank of examples of mechanical, optical and software devices
- Quick mock-ups of solutions in cardboard, jig or visual marker
- Presentation of the selected solutions to supervisors at the end of the day
Assessment and documents
Knowledge test and end-of-course evaluation at D+1; the solutions proposed for the workstation studied are presented and discussed at the end of the workshop. Numbered certificate, verifiable online, for each participant; training report and device sheets handed to the company.
Bilingual materials for every participant; each classroom course comes with its digital twin on OmniLearn.
Frequently asked questions
Does an error-proofing device require a large investment?
Rarely. Many effective devices are jig shapes, stops or markers. Sensors and automatic checks come later, when the risk justifies them. The workshop looks for simple solutions first.
How do we know a device still works?
By a periodic verification with a bad reference part, which must be rejected. The result is recorded, and a reaction is defined if the device does not respond. This verification is part of the control plan.
Does poka-yoke apply in agri-food?
Yes: checking the right packaging or label by barcode reading to prevent an allergen error, checking the presence of the cap, locking a recipe. The principles are the same as in assembly.
Who should attend?
Methods, maintenance, quality and operators or team leaders from the workstations concerned. The best ideas for devices often come from the people who perform the task every day.
Practical information
- Duration
- 1 day
- Audience
- Methods, maintenance, quality, production engineering, team leaders and operators
- Prerequisites
- No prerequisites
- Group size
- Groups of 6 to 12 participants, in-company
- Format
- In-company, face to face on your site
- Language
- French, Darija or English; bilingual materials
- Funding
- OFPPT special training contracts (TFP), GIAC, Maroc PME: we prepare the applications with you, at no extra cost.
- Programme customisation
- Programme adapted to your procedures, your equipment and your audience
Organise this course
Price and dates on quote, depending on your headcount, your site and your preferred period.
Request a quoteDownload the PDF sheetCall +212 661 863 618Going further
Our consultants can also support the project on your site. Organisational Diagnostic and Tech-Enabled Transformation
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Book a call with a consultant or request an in-company session: we adapt the programme to your procedures and your audience.