Poka Yoke - Mistake proofing

Poka Yoke - Mistake proofing


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About The Event


Based on profound wisdom 'To err is human' & 'Prevention is better than cure'; Poka yoke is a technique driven approach to achieve Zero Defect Quality.

Although being an Industrial Engineer, Mr. Shigeo Shingo, the founder of Poka Yoke realized the limitations of statistical techniques & devised a three step process of ZQC (Zero Quality Control) consisting of:

  •  Source Inspection
  •  100 % Inspection
  •  Stop the process in event of defect

The common sense approach relies primarily on machine vigilance rather than human vigilance because machine never sleeps!

The aim is to:

  •  Help people do it right first time.
  •  Prevent mistakes from occurring.
  •  Achieve 100 % defect free production.

It is a system of techniques, which uses simple, low cost, fast, effective Poka Yoke devices to inspect automatically for errors or defective operating condition. Poka Yoke finds application not only in manufacturing processes but also in service processes, office administration & transaction processes.

Due to proven results, even the standard ISO/TS16949: 2002(E) includes under clause - 'The organization shall use error-proofing methods in their corrective action process.'


Session 1


  • Present Industrial Scenario. 
  • Introduction to  Poka-yoke
  • Methodology of Poka-yoke 

Session 2:

  •  Advantages of Pokayoke
  •  Application  of Pokayoke in  Real Life
  •  Applications of Pokayoke  in Automotive  Industries

Session 3:

  •   Case studies of Pokaya  ( Based on Participants area  of work following  methodology of Poka-yoka ) 
  •   Question and Answer session. 

Who Should Attend?

Machine & Equipment Operators, Supervisors, Officers, Engineers & Managers or anybody interested in Poka Yoke.

After attending the course the participants shall be able to apply Poka Yoke in their own operations. Typically within a week they achieve 70-80 % reduction in defects with little or no capital investment.



​Expert ​


38 years of experience in Maintenance management in Tata Motors. Authorized trainer for TPM Consultancy, Quality Circles Activities, Kaizens, PokaYoka, Safety best maintenance practices, Asset management, 5S, SCM etc. He headed entire Plant level TPM implementation activities.  

Post Diploma in Material Management, Diploma in Mechanical engineering

Professional Experience

  •  Worked in Machine Reconditioning for 14 years
  •  Certified TPM Facilitator (Course conducted by TPM Club of India ,Bangalore)
  •  Trainer in TPM Process and Implantation in Marathi and English for all levels in the organization 
  •  Worked as Central TPM Coordinator for implementation of TPM In Tata Motors Car Plant Pune
  •  Trainer for Quality Circle activities at all levels of organization
  •  Participated in National competition for Quality Circles and won Par Excellence award for the team
  •  Worked as facilitator for Quality Circle Movement
  •  Worked as facilitator Total Quality Management
  •  Have knowledge of Industrial Safety Procedures.
  •  Trainer in Kaizen Activity
  •  Trainer for Self Managed Teams

Medium of Instruction: English, Hindi & Marathi.