Leading mistake/error proofing (Poka Yoke) activities

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This standard covers the competences required for leading mistake/error proofing (Poka Yoke) activities, which is a method of making an activity 'foolproof'.  It involves leading the application of the principles and procedures of mistake/error proofing to the chosen activity, to enable worksheets to be produced for the activity that identify the problem, evaluate any actions to be taken, and indicate the benefits to be gained.  Typically, worksheets would focus on the description of the mistake/error identified, the containment action taken, the root cause of the mistake/error and the permanent corrective action to be taken.  You will be required to lead trials on the suggested improvements, which will include confirming their effectiveness, cost and complexity.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the activities that you cannot solve, or that are outside your responsibility, to the relevant authority.  You need to ensure that all necessary job/task documentation and analysed data is completed accurately and legibly.  You will be expected to take full responsibility for your own actions within the activity, and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of mistake/error proofing, and will provide an informed approach to the techniques and procedures used.  You will need to understand the principles and application of mistake/error proofing, in adequate depth to provide a sound basis for carrying out the activities to the required criteria.

Applying and advising on safe working practices will be a key issue throughout.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. use information and data to approve the selection of a suitable process on which the mistake/error proofing activity is to be carried out
3. lead the application of the mistake/error proofing process to the chosen activity
4. analyse the data using appropriate techniques and confirm valid conclusions
5. evaluate recommendations and lead the production of worksheets for the activity that identify the problem and actions to be taken
6. agree suitable solutions, and manage the carrying out of agreed trials to measure the effectiveness of the solution
7. lead and co-ordinate the implementation of the optimum solution
8. lead the measurement and documentation of the results

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. how to define a mistake/error proofing activity, and the benefits of carrying this out
3. the difference and benefits between mistake/error proofing and prevention and detection
4. how to plan the resources and time needed to carry out the agreed activity
5. the selection criteria used to determine a suitable product or process on which to carry out the mistake/error proofing activity
6. how mistake/error proofing can lead to zero defects
7. the relationship between errors and defects
8. the different types and range of mistakes
9. how defects originate in products or processes
10. how the role of source inspection contributes to the reduction of defects
11. the application of mistake/error proofing (poka yoke) tools
12. the type of mistake/error proofing documentation, and the information it should contain
13. the analysis and charting methodology used for mistake/error proofing
14. the financial implications of mistake/error proofing projects
15. the relationship between mistake/error proofing and other continuous improvement processes
16. how to undertake trials and measure the effectiveness of mistake/error proofing projects
17. the different types and range of mistake proofing devices used
18. the roles and responsibilities of individuals within a mistake/error proofing team (including facilitator, timekeeper, scribe)
19. the extent of your own authority within the activity, and to whom you should report in the event of problems that you cannot resolve

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1.    Lead the activities within your area of responsibility to include all of the following:

1. set out and communicate the purpose of the improvement activities
2. involve the team in planning how the improvement activity will be achieved
3. ensure each team member has individual objectives and understands how these objectives contribute to the overall improvement objective
4. provide advice and support the team to achieve both team and individual improvement objectives
5. motivate the team to present their own improvement ideas
6. encourage the team and/or individuals to take the lead where appropriate
7. agree the implementation of the improvement ideas
8. negotiate any physical and/or financial resources required to implement the improvement activity (where appropriate)
9. monitor the progress of improvement activities
10. deal with any organisational problems identified during the improvement activity

 

2.    Identify the benefits of mistake/error proofing in terms of:

1. improved quality/compliance
2. reduced costs
3. delivery or service
   
    

3.    Lead the creation of a worksheet of the mistake/error proofing activity, identifying:

1. the description of the mistake/error identified
2. the containment action taken
3. the root cause of the mistake/error
4. the permanent corrective action to be taken
   
    

4.    Approve suitable solutions and determine their:

1. effectiveness
2. cost
3. complexity

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3

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2028

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Current

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Original

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Enginuity

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SEMBIT421

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Associate Professionals and Technical Occupations, Business and Finance Associate Professionals, Business Management, Business, Administration and Law

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2127

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Engineering; business; improvement; techniques; mistake proofing; error; proofing; Poka Yoke; foolproofing

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