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Error proofing is using a structured approach to eliminate errors and ensuring quality in your work processes. Error proofing is also known by many names such as Poka Yoke, which is a Japanese concept that is widely attributed to Shigeo Shingo. The primary aim of such error proofing processes is to help people and processes work right, the first time.

Aims and Objectives

The aim of the programme is to enable the delegate to:

  • Gain an understanding of error proofing

  • Identify root causes of error

  • Gain a knowledge the tools and techniques used in error proofing

  • Be able to reduce and eliminate waste

  • Be able to train others on error proofing methodology

This course is ideal for

  • Leaders

  • Supervisors

  • Managers

  • Decision makers

  • Business process owners

  • Operational and support staff from both the manufacturing and service sectors

Course Content

  • Introduction to error proofing

  • The root causes of error and how to identify them

  • The costs of error - rework, extra work, scrap and wastage, warranty costs, inspection costs

  • Root Cause Analysis Tools for Mistake-Proofing

  • How does error proofing work

  • Create an error proofing culture within a company

  • Positive and negative types of cultures

  • Error proofing function and devices

  • General failure modes

  • Zero Quality Control (ZQC)

  • Components of ZQC

  • How to achieve ZQC

  • Case studies associated with error proofing

Delegates Prerequisites

Attendees must have a good working knowledge of their own industry sector.

Course Methodology

This course is an instructor led classroom based environment, conducted by a leadership expert. The classes will be conducted over 2 days. The course consists of a blend of lectures, application, projects and exercises. All other materials will be provided to the attendees in the classroom environment. At the conclusion of the course, there will be an exam and a certification can be obtained upon attaining the passing grade.


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