POKA-YOKE ZERO DEFECT OPERATIONS BY MISTAKE PROOFING THE PROCESS

Featured Speaker:  Dr. Enrico C. Mina
TQM & Supply Management Consultant
November 27, 2020
9:00am – 12:00nn
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Regular Rate           Php 1,499.00 + VAT starting November 21, 2020
Early Bird Rate        Php 1,399.00 + VAT until November 20, 2020
Group Rate              Php 1,299.00 + VAT per pax for 5 or more pax

Inclusive of the Webinar Session and the Digital Certificate
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Introduction

All work in an organization is performed through processes. Human resources are an indispensable element is every process. But human beings are imperfect and prone to committing mistakes. A high-quality process needs to operate at a very high level of reliability and predictability. How can such a process be possible given human fallibility?

The answer lies in a system of procedures, devices, and other interventions that make doing the right things easy and the wrong things difficult, or at least alert the human operator that a mistake has been committed or is about to be committed. This system is called Poka-Yoke, a Japanese term that means “mistake-proofing.” It was first developed in Toyota Motors of Japan by Shigeo Shingo, who assisted Taiichi Ohno in creating the Toyota Production System, also known as the Just-in-Time Production or Lean Manufacturing. The TPS is recognized as the world’s most efficient manufacturing system. JIT cannot allow mistakes because they would derail the finely-balanced operations. If mistakes can be prevented, then the operations will flow smoothly and productively, producing outputs of high quality at the shortest cycle time and at the least cost.

This course teaches the fundamental principles and concepts of the Poka-Yoke System.

Learning Outcomes

            At the end of this course, the participants will be able to:

1. Understand and explain the basic principles and concepts behind poka-yoke
2. Apply these principles and concepts to the development of a poka-yoke solution to an actual operating problem in their respective organizations.

Course Outline

1. The changing business environment
   1. More demanding customers and tougher competition
   2. The need for greater competitiveness for survival and growth
2. The primary purpose of a business enterprise
   1. To satisfy its customers by offering better value than competitors
   2. Satisfied customers lead to higher sales, market share, growth, and profit
   3. Customer goals:
      1. Quality
      2. Cost
      3. Delivery
3. Process and Results
   1. Process elements: human resources, machines, materials, methods, measurements, and work environment
   2. Cause-and-effect relationship between process element interaction and the results or outputs
   3. Process control through the six elements
4. Two Approaches in Dealing with Human Errors
   1. To assume that errors are inevitable
   2. To believe that all kinds of errors can be eliminated or prevented
5. Inspection Techniques
   1. Judgment inspection
   2. Informative inspection
   3. Source inspection
   4. Sampling vs. 100% inspection
6. Three Strategies for Zero Defects
   1. Don’t make it if the customer does not need it.
   2. Make it to withstand any use.
   3. Once you’ve made it, use it right away.
7. Different Kinds of Human Errors
   1. Forgetfulness
   2. Errors due to misunderstanding
   3. Errors in identification
   4. Errors made by amateurs
   5. Willful errors
   6. Inadvertent errors
   7. Errors due to slowness
   8. Errors due to lack of standards
   9. Surprise errors
   10. Intentional errors
8. Approaches to Mistake-Proofing
   1. Mistake-prevention in the work environment
   2. Mistake prevention upstream
   3. Mistake detection through self-checks
   4. Prevention of the influence of mistakes
9. Basic Poka-Yoke Functions
   1. Prediction
   2. Detection
   3. Sub-functions
      1. Shut-down
      2. Control
      3. Warning
   4. Detection methods
      1. Contact
      2. Non-contact
      3. Fixed-value
      4. Motion-step
   5. Identification of items
      1. By weight
      2. By dimension
      3. By shape
      4. By color
   6. Deviation detection
      1. Process sequence method
      2. Process-to-process sequence method
      3. Deviation from fixed values using a counter
      4. Odd-part out method
      5. Critical condition detection
      6. Using a go/no-go gauge
      7. Using a critical-items checklist before starting operations
10. Poka-Yoke Devices and Systems
    1. 1. Many possibilities today because of the advancement of technology
       2. Can be simple, inexpensive, and easy to install
       3. Sources of ideas
11. Product and Process Design
12. Eight Principles
13. Next Steps

Facilitator

            The course facilitator is Dr. Enrico C. Mina, an Associate Professor at the Ateneo Graduate School of Business who has had 40 years of experience in the field of TQM, particularly in San Miguel Corp., United Laboratories, Inc., and Kaizen Management Systems, Inc.

Schedule

            The course is held online via Zoom over a three-hour period.

RESOURCE SPEAKER – Dr. Enrico C. Mina

• Dr. Enrico C. Mina is an Associate Professor of the Ateneo de Manila University Graduate School of Business, who teaches various economics and business management courses. He has had 27 years of teaching experience, the bulk of which was at the post-graduate level at the AGSB. Dr. Mina returned three years ago from a three-year teaching engagement as Senior Lecturer at the Department of Business Studies of the Papua New Guinea University of Technology at Lae City, Morobe Province, Papua New Guinea. While there, he taught courses in basic economics and management and acted as the Director of the Executive MBA Program, which he helped conceptualize and design and in which he taught six courses.
• Dr. Mina also has extensive experience in the business world as manager, consultant, and trainer, particularly in the areas of Total Quality Management and kaizen (continuous improvement), operations and supply chain management, and strategic management.
• Dr. Mina is a faculty member as well at the Ateneo School of Government, teaching Applied Economics in the Public Sector. At the same time, he teaches MBA courses at the Ateneo School of Medicine and Public Health, whose curriculum seamlessly integrates medical science and management.
• He has written and published several research papers and original cases. While at PNG University of Technology, he wrote a textbook entitled Introduction to Economics for use by the university’s Department of Open and Distance Learning’s Adult Matriculation Program. He has also been the adviser of the Governance Innovation Report (equivalent to a masteral thesis) of 24 students at the Ateneo School of Government.
• Dr. Mina obtained his Doctor of Business Administration (DBA) degree from De La Salle University-Manila in 2011, his MBA from the Ateneo Graduate School of Business in 1979, and two undergraduate degrees (AB major in Economics and BSBA major in Management, Summa cum Laude) from De La Salle University-Manila in 1973.

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Thank you and enjoy!

Keep safe and God Bless!