Quality & Operational Excellence

Mistake-Proofing and Poka-Yoke

Mistake-proofing designs processes so that errors cannot happen or are detected immediately. This course covers poka-yoke principles, types of human error, prevention and detection devices, contact, fixed-value and motion-step methods, applying mistake-proofing in manufacturing, services and IT, and evaluating effectiveness.

5 days Classroom or live online English

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Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Training and warnings cannot eliminate human error, but good design can. You will learn to design error-proof processes.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Error analysis exercises, device design workshops, examples from many industries and case studies.

Course objectives

What you'll take away.

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

Explain types of human error
Distinguish prevention and detection mistake-proofing
Apply poka-yoke methods
Design mistake-proofing devices and controls
Apply mistake-proofing in service and digital processes
Evaluate effectiveness of solutions

Target audience

Who should attend.

This course is suitable for:

Quality and process engineers
Production supervisors
Service designers
Continuous improvement practitioners
Product designers

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Error analysis
Device design
Process design
Creativity
Evaluation

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Human Error

09:00–10:08Types of errors
10:08–11:00Why training is not enough
11:00–11:30Coffee break
11:30–11:45Why training is not enough (continued)
11:45–12:53Examples
12:53–14:00Exercise

Day 2Poka-Yoke Principles

09:00–10:08Prevention and detection
10:08–11:00Control and warning
11:00–11:30Coffee break
11:30–11:45Control and warning (continued)
11:45–12:53Methods
12:53–14:00Workshop

Day 3Designing Devices

09:00–10:08Physical devices
10:08–11:00Sensors
11:00–11:30Coffee break
11:30–11:45Sensors (continued)
11:45–12:53Low-cost solutions
12:53–14:00Design exercise

Day 4Services and IT

09:00–10:08Forms and checklists
10:08–11:00System validation
11:00–11:30Coffee break
11:30–11:45System validation (continued)
11:45–12:53Service examples
12:53–14:00Case study

Day 5Effectiveness

09:00–10:08Testing solutions
10:08–11:00Maintaining devices
11:00–11:30Coffee break
11:30–11:45Maintaining devices (continued)
11:45–12:53Scaling
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon UK certificate of attendance. Smart Horizon UK programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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