Mistake Proofing


Even in businesses where processes are well controlled and people are well trained, human errors still inevitably occur on a chronic basis. Unfortunately, the financial consequences of those human errors on business performance can be very high.
Mistake Proofing (or Poka-yoke) was “invented” in 1961 by Dr. Shigeo Shingo to achieve ultra-low defect levels by tackling human errors in the workplace head-on. Shown to be remarkably successful, Mistake Proofing programs and applications can now be found world-wide.
This technique is most often deployed in production and design processes and is commonly integrated into many improvement programs and quality systems.

There are two main focuses of mistake proofing:

  • Prevention: To prevent a human error from happening.
  • Detection: To immediately identify when an error has occurred and enable containment at source.

This course is designed to provide participants with the theoretical and practical knowledge needed to implement mistake proofing in both design and manufacturing activities. The primary emphasis is upon the achievement of major improvements in overall manufacturing performance


We combine theory with a workshop in which participants utilize their new knowledge to develop mistake-proofing applications that are ready to be implemented upon leaving the workshop.

  • Theory is immediately applied during the workshop as students brainstorm and create mistake-proofing ideas using workshop concepts.
  • Ideas are critiqued and refined to create applications that are immediately applicable.

What You Will Learn

  • Unit 1.  Introduction
  • Unit 2.  What is Mistake-Proofing?
  • Unit 3.  Why Bother?
  • Unit 4.  Who Performs Mistake-Proofing? Where?
  • Unit 5.  Inspection Systems
  • Unit 6.  Mistake-Proofing Applications
  • Unit 7.  The Mistake Proofing Process
  • Unit 8.  Group Mistake Proofing Exercise
  • Unit 9.  MP Program Management & Sustainability
  • Unit 10.  Action Plan / Wrap-up

Training Outcomes

Graduates will have the theoretical and practical knowledge needed to implement mistake proofing in design and manufacturing activities, and will thereby have the ability to make a significant contribution to improving their company’s manufacturing performance. During the course, participants will be required to brainstorm and develop mistake-proofing applications that are relevant to their own processes, and will be expected to have refined these ideas to the point that they will have at least one mistake-proofing application that is capable of being implemented within their own organization.

This course is primarily targeted at the technical, engineering, maintenance and production personnel who have the responsibility for achieving ultra-high performance levels.


Training Overview

Our Courses

Manufacturing Control Systems

Quality & Environmental Systems

Strategy & Execution

Improvement Tool Kit

Presentation & Leadership Skills

Full Course List


SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.