Program name:

Envisionment:

Increase " First time right and every time right "consciousness in Process
through a Pokayoke workshop

Audience Analysis
Why have you been asked to design this training program?
To create the mistake less Process

Who are the learners?

Manufacturing,Quality,Purchase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)
What is their profile in terms of Age, Qualification, Experience?
Manufacturing,Quality,Purchase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)
age - Upto 15 years experience)
What are the points of commonality between the learners?
Directly involved in Process which connecting (Supplier-Input-Process-Output-Customer)
What are the cultural, language differences (if any) among the learners?
English Language

Why do the learners need to attend this program?

They can learn, how to identify the mistake opportunities and how to create the misteke proofing for the same

What is their current level of knowledge on the subject of this program? What other similar programs have they attended in
Participants may aware few examples of Pokayoke (mistake Proffing). But this program focus Identifing the mistakes to arre
Paticipants may attends few quality or process improvements programs where they may aware the concept level.

What should the learners be able to do at the end of this program?

At the end of the program learners can able to identfy the mistake opportunities and they solve the issues by developing po

What is likely to be their attitude towards the proposed training program? What is likely to be their motivation levels in attend
program?
Positive leraning attitute. Learning and implementation level
What should the learners know before attending this program?
Mistakes,defects,customer complaints,rework in their process
How many people need to go through this program?
Minimum batch of 25 members at a time
Where are they located?
Near training venue
What kind of learning experiences have they been through in the past? (basically to judge their ability to learn from various
OJT, CBT, WBT
Class room training and on the job experience
Is there an indicative duration that has been shared with you?
Yes.10 days before

Are there any other constraints that we need to know in designing this intervention? Can they be spared for x number of day
program? Is there a deadline by which the programs need to be completed? Are there travel constraints?
Its designed for 1 day program. classroom training
Is pre-work possible?
Identification of Mistakes,defects,customer complaints,rework in their process
Is post-work a possibility?
Yes. Project identification and pokeyoke implementation

How much can we count on the immediate managers to reinforce the learning?
Maximum
Task Analysis

What should the learners be able to do at the end of this training program?
At the end of the program learners can able to identfy the mistake opportunities and they solve the

Program name:

me right and every time right "consciousness in Process

ke workshop

Audience Analysis

o design this training program?

rocess

ase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)
of Age, Qualification, Experience?
ase,Maintenace & Manufacturing Engineering Department members (Entry Level to Mid Level)(Upto 40 Years
nce)
monality between the learners?
which connecting (Supplier-Input-Process-Output-Customer)
ge differences (if any) among the learners?

o attend this program?

fy the mistake opportunities and how to create the misteke proofing for the same

knowledge on the subject of this program? What other similar programs have they attended in the past?
examples of Pokayoke (mistake Proffing). But this program focus Identifing the mistakes to arrest the mistake.
quality or process improvements programs where they may aware the concept level.

able to do at the end of this program?

arners can able to identfy the mistake opportunities and they solve the issues by developing pokayoke.

ude towards the proposed training program? What is likely to be their motivation levels in attending this

rning and implementation level

ow before attending this program?

omplaints,rework in their process

o through this program?

ers at a time

ences have they been through in the past? (basically to judge their ability to learn from various media) ILT,

he job experience

n that has been shared with you?

nts that we need to know in designing this intervention? Can they be spared for x number of days for the
by which the programs need to be completed? Are there travel constraints?
m. classroom training

ects,customer complaints,rework in their process

d pokeyoke implementation

he immediate managers to reinforce the learning?

Task Analysis

rs be able to do at the end of this training program?

am learners can able to identfy the mistake opportunities and they solve the issues by developing pokayoke

ues by developing pokayoke.

Program Name:

Terminal Objectives (TO)

( What the participant will be able to do at the end of this training
program)

By the end of the training program, participants will be able to:

1

Introduction

Created by:

Enabling Objectives (EO)

Level 1
( What the participant should be able to do if he ha

By the end of the training program, participants wil

1.1

1.2

Zero Defects & Costs

2.1
2.2

Waste Management

3.1

3.2

3.3
4

Zero Defects Quality (ZDQ)

4.1
4.2

Understanding Process Errors

5.1
5.2

Four Elements of Zero Defect Quality

6.1
6.2
6.3
6.4
6.5

6.5
7

Seven steps to Poka yoke

7.1

7.2
8

Poka yoke methods

8.1

8.2

8.3

8.4
8.5

Summary

9.1

9.2

9.3

Created by:

Date:

Enabling Objectives (EO)

Level 1
What the participant should be able to do if he has to do the relevant TO)

By the end of the training program, participants will be able to:

Importance of "Zero Defects" Concepts

Kaizen

Tool Kit Comparison

Cost of Defects

Value

Waste

Elimination of Waste
Concept ZDQ
Benefits & How to achieve
Process Vs Quality defects
Human Mistakes

4 Components of ZDQ
Point of Origin Inspection
100% Audit checks
Immediate feedback
Pokayoke

Pokayoke
Guidelines to Pokayoke attainment

Govern the Process

Methods for Poka yoke

Contact Method

Counting Method

Motion Sequence Method

Types of sensing devices

3 Rules of Poka yoke

Developing Poka yoke

Revison

Methodology
(How the content will be delivered)
Content
( The content that needs to be covered if the
participant has to do the relevant EO)

Zero Defect
First time right & every time Right
Zero Rework
What is Kaizen
Time Vs Savings
Incremental improvements
Major Tools
Compasion of Kaizen , 6sigma& Lean
Rework
Scrap
Inspection Cost
Warranty Cost
1-10-100 Rule
what is Value?
Who defines Value?
Value in various business, process?
What is Non Value Added?
What are the wastes?
Wastes in various business,Process?
identification of wastes
Elimination of wastes
Zero is the GOAL
Process Control
ZDQ Makes Work Easier
Process Control
Relationship
What Causes Defects
What is Human Errors?
Types of Human Errors
Relationship between defects and Human Errors
How many Components in ZDQ
What are the compenets of ZDQ
3 Approaches of Inspection
Focus on Prevention
100% Inspection
assemptions
Importance of Feedback
Differs from traditional method
What is pokayoke

What will the faculty do

Explaination
Discussion
Examples
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Discussion
Discussion
Discussion
examples
Explaination
Explaination
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination

Importance
Quality Process
Utilize a team Environment
Elimination of Errors
Eliminate the Root Cause
Do it right the first time
Eliminate NVA
Implement Kaizen
Control Approach
Warning Approach
Contact
Counting
Motion-Sequence
Physical Contact
Energy Contact
Contact Devices
Contact Methods
Sensors
No of times
No of Parts
Concept
Sensors
Physical Contact
Touch Switch
Warning sensors
Energy Sensors
Dont Wait
Do it
Now
Problem discussion
Analysis the Root cause
Pokayoke development
Concept ZDQ
Human Errors
Poka yoke

Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion
Discussion
Explaination
Explaination
Explaination
Discussion
Discussion

Methodology
ow the content will be delivered)

Time(Mins)

Logistics
(Special aids, arrangements to
be made)

What will the learners do

To Understand
Partcipate in discusssion
Provide examples in their process
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
Provide examples in their process
To Understand
To Understand
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion

6
6
4
6
10
4
6
10
4
4
4
4
6
6
4
6
10
10
8
6
10
6
8
6
8
10
6
8
8

Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand

10
6
6
6
6
6
6
6
6
6

Projector
Screen
Speaker
White Board
4 colour Board Markers

Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion
Partcipate in discusssion
To Understand
To Understand
To Understand
Partcipate in discusssion
Partcipate in discusssion

6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
4
4
4
8
8
6
8
8
8

Evaluation
Remarks/
Guidelines
(Books, manuals, website
references..)

Zero Defects Quality Book by Mr.Shigeo shingo

Human Error Prevention - Materials from MIQ