Fundamentals of Error Proofing: The Path Toward Zero Defects

Error-proofing, or poka yoke as it’s often called, is an over-arching strategy to help organizations achieve zero defects in their manufacturing processes.  Developed and popularized in Japan by Shigeo Shingo in the 1950’s, these methods and techniques can now be found in manufacturing process across multiple industries, embedded into a wide range of consumer products, and employed by innovative quality and process professionals around the globe.

In their purest form, an error-proofing device prevents a defect from being made. By using simple sensors and mechanical devices, engineers can design assembly and test fixtures that prevent the processing the parts configured in an incorrect fashion. Other error proofing device can prevent a defect part from moving onto the next process. And still others simply assist the operators in not making a defect.

When combined with other strategies such as Statistical Process Control, Layered Process Auditing, and Root Cause Analysis, a systemic deployment of error proofing can help an organization DRIVE THEIR DEFECTS TO ZERO.

In this course, “Fundamentals of Error Proofing: The Path Toward Zero Defects”, students will learn the history and basic strategy of error proofing, along with gaining practical applications of this approach. The course is broken into several sections: 

• Error Proofing as a Path to Zero Defect with Manufacturing Academy instructor, Mike Vella

• Basics examples of Error Proofing

• A Case Study of Error Proofing in a CNC Machining Application

• Sensor-based error proofing designs

• Integrating error-proofing into your quality management system

• Error-proofing and lean manufacturing

By the end of this course, students will understand the major approaches of error-proofing and be armed with the knowledge they need to start deploying these strategies in their manufacturing processes.

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