Delivering Sustained Success
Countries Regional

Zero Defects Through Poka Yoke

  • Overview
  • Course Outline
  • For Whom
  • Other Details
  • Related Trainings
Does your organization need a solution that can prevent errors and defects from occurring?

Poka Yoke, or error-proofing has gained popularity in recent years because organizations have discovered that defects are better off “prevented” rather than “detected.”

Shigeo Shingo is credited with creating the concept of zero defect and the techniques of Poka-Yoke, the Japanese term for error-proofing or mistake-proofing.  The approach seeks to remove the causes of defects; or when this is impossible, to inspect each item in an inexpensive manner to ensure that it passes the quality threshold - with no defects.

This compact course will help participants to get started on developing and implementing an error-proofing system for their organizations.

Special note to Automotive Industry Manufacturers: As per the IATF 16949:2016 requirements clause 10.2.4, organizations that intend  to be certified to IATF 16949:2016 are required to practice error-proofing and apply error-proofing devices. Therefore, this programme provides a good foundation into the understanding of the error proofing concept and how it is applied to comply to the requirements of the standard.

  • To identify the functions, characteristics and advantages of a Poka-Yoke methodology
  • To distinguish the differences between a Poka Yoke system and an inspection system.
  • To identify where Poka-Yoke can be used and implemented effectively in the organization
  • To provide the roadmap for the implementation of a Zero Defect Quality (ZDQ) System.

Upon completion of the training, participants are able to :
  • understand the Poke Yoke concepts.
  • appreciate and understand how to use Poka Yoke to achieve zero defect quality in an organization.
  • integrate the Poka Yoke methodology into corrective action and preventive action.


  • Introduction
  • Zero Defect Quality
  • The 6 Principles of Error Proofing
  • Poka Yoke Methods
  • Types of Poka Yoke devices
    • (This includes real life examples, exercises, case studies and group discussions to further strengthen understanding and application.)
  • Poka Yoke implementation with Root Cause Analysis
  • ZDQ & Poka Yoke Implementation
  • Summary and Questions & Answers Session.
This course is designed for front line managers, engineers or executives who are involved in the development and implementation of Poka Yoke as part of their quality and profitability improvement initiatives.

Note : Courses on Quick Changeover, Total Productive Maintenance (TPM) and 5S are available and may be of benefit for application in conjunction with Poka Yoke.
All Neville Clarke tutors are full time consultants and trainers.  The tutor assigned is an experienced professional with practical application of Poka Yoke, who will be able to help you identify opportunities to error-proof processes and activities in your organization.

This is a one-day course running from 9.00 am to 5.00 pm.

Code Title Location
LEA01 Lean Manufacturing Value Stream Improvement Philippines
LEA03 Lean Office: Improving Transactional Processes with Lean Philippines
LEA06 Certified Lean Practitioner Philippines
LEA07 Certified Lean Expert Philippines
LEA08 Certified Lean Master Philippines
LEA11 Total Productive Maintenance (TPM) : Key to Production Effectiveness Philippines
LEA16 Standard Operations with Training Within Industry (TWI) Philippines
LEA18 The A3 Report: A Lean Problem Solving and Reporting Process Philippines
LEA19 An Introduction to Lean Warehousing Philippines
LEA23 Lean Supply Chain Management : Extending the Lean Enterprise Philippines
LEA24 Lean Deployment Management with Hoshin Kanri Philippines
LEA31 Advanced Pull Manufacturing with Heijunka Philippines
LEA33 Overall Equipment Effectiveness (OEE) Explained Philippines
LEA34 A Guide to Kaizen Implementation Philippines
Available Dates
Philippines, Manila   1 Day
30 October 2019


Not ready to register for public training just yet? Want to talk?

"I need more information..."
"I am looking for in-house training..."

If you have any of the above concerns, let's talk!


Contact Us