Error & Mistake Proofing training agenda:
1. Fundamentals of Error/Mistake Proofing
• What is Poka-Yoke? Definition and purpose
• Errors vs. defects — key distinction
• Shigeo Shingo’s classification
• Benefits of implementation (quality, cost, efficiency, motivation)
• Types of solutions: control vs. warning approach
• Levels of protection (preventive, assisting, detecting)
2. Poka-Yoke Methods and Applications
• Contact methods
• Counting methods
• Motion-sequence methods
• Sensor categories: physical contact sensors, energy-detection devices, warning sensors
• Use of photoelectric, fiber-optic, vibration, and force sensors
• Passive solutions (fixtures, asymmetry, design-based prevention)
3. Human Error and Process Variation
• 10 most common causes of errors
• Human Error Analysis (HEA) structure
• Interview-based root cause identification
• Eliminating process-based contributors (machines, materials, standards)
4. Error-Proofing in Compliance with IATF 16949
• Relevant clauses: 8.3.3.2, 8.3.5.2, 8.5.1, 8.5.6.1.1, 10.2.4
• Documentation expectations (PFMEA, Control Plan, testing frequency)
• Use of master samples, Red Rabbit, calibration & validation
• Temporary process changes and restart verification
5. Reverse FMEA to Validate Poka-Yoke
• Purpose and methodology
• Live-process verification vs. paper-based assumptions
• Simulating errors safely
6. Effective Management & Sustainment
• Layered Process Audits (LPA) checkpoints
• TPM integration for device reliability
• Calibration and bypass prevention
• Visual management and labeling
7. Hands-on workshops on the production line (available for in-house training sessions)
Target Audience:
Quality department personnel
Customer quality engineers
External customer quality representatives
Implementation teams
Process engineers and technologists
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Automotive Quality Solutions
Training program
PDF file
Automotive Quality Solutions
The Error & Mistake Proofing training will enable participants to:
1. Understanding the Concept and Importance of Error & Mistake Proofing
Participants will gain a solid understanding of Error & Mistake Proofing and its critical role in quality management. They will learn why eliminating errors at the production stage is essential to delivering high-quality products.
2. Application of Error & Mistake Proofing Tools and Techniques
Participants will become familiar with key tools and methods, including FMEA (Failure Mode and Effects Analysis), Poka-Yoke, Mistake Proofing, and quality planning. They will learn how to effectively apply these techniques to reduce error risk and ensure consistent product quality.
3. Enhancing Organizational Culture
The training will support the development of a quality-driven culture by encouraging responsibility and proactive error prevention. Participants will be empowered to promote continuous improvement and a mindset focused on quality across all levels of the organization.
Automotive Quality Solutions
Price:
Training dates:
March 18, 2026 – online training session
Price:
447 EUR per participant
A 10% discount applies to the second and each additional participant from the same plant.
Payment Terms:
Invoices will be issued after the service has been delivered. The payment due date is 30 days from the invoice issue date.
Price includes:
Participation in the training
Training materials
Certificate of completion
Additional Resource:
Be sure to read our article Error proofing vs. Mistake proofing
