Mistake-Proofing FAQs

What is a “Mistake-Proofing” device?

Something put in place, to keep an error from occurring. It is typically a physical device, but it may be a procedure, software change, or something else – depending on the application.

What is a Poke-Yoke?

Japanese for Mistake-Proofing device.

What’s the bottom line? What is our pay-back?

You have to determine that. What is it worth that a particular defect doesn’t ever happen again? Financially, the payback can run from a few dollars to hundreds of thousands, depending on the specific problem. For manufacturing, we have an on-line "Cost of Defects" calculator you can use to help determine costs.

Is a Mistake-Proofing device expensive?

Most often, Mistake-Proofing devices are quite inexpensive. Simple is better and so is inexpensive. However, sometimes you may have to spend a little, depending on the involvement.

Who designs the device?

A Mistake-Proofing device can be designed by anyone. However, we have generally seen the best results when the solution is team-based. Cross-functional groups are best.

We are very busy. How much time does it take to Mistake-Proof something?

We recommend using a team of 4-8 people. It will typically take this group 3-4 hours to examine the defect, determine the source error, and brainstorm for a solution. This group will also make the plan for education, implementation, and rollout.

Does Mistake-Proofing only work for manufacturing?

Mistake-Proofing applies to any aspect where people are involved, be it manufacturing, service, or healthcare – even at home.

Healthcare is different than just making a product. We deal with people, how can we Mistake-Proof that?

Mistakes come from people making errors like forgetting something or misidentifying something. Human errors are common no matter what field you are in.

My department has several problems. Can we Mistake-Proof them all?

Yes, but best to do them one at a time. Mistake-Proofing is very narrowly focused for a specific problem. If sweeping changes are needed, you would be better off having a Kaizen event.

Is your course available on-line?

No. Our specialty is hands-on. We have found that real expertise comes from doing.

What expenses are involved with an on-site course?

A day-rate is charged, plus actual travel expenses. Each participant will receive a workbook and other materials, which range from $10 - $30, depending on the needs of the event.

If people would pay closer attention, we wouldn’t need Mistake-Proofing.

If “Ifs and Buts were Candy and Nuts, we’d all be happy at Christmas”. But seriously, people do try hard, yet we all make mistakes. How many mistakes have YOU made today?

Why are on-site programs two days long?

The first day is spent laying the basics with our standard seminar. The second day is spent with teams ACTUALLY Mistake-Proofing problems on your own floor. Each team of 4-8 people will probably come up with real devices for two problems.

We don’t want another “Flavor of the Month.”

We agree. A “Flavor of the Month” can leave a bad taste if not adequately supported by the management. We provide you with this very powerful tool and we help guide you towards making a change in your local culture. After we leave, it is up to you to keep practicing. With a few events under your belt, the Mistake-Proofing event will go quickly.

What happens after you leave? How do we continue this?

We strongly recommend that you identify a “Mistake-Proofing Champion,” someone who enjoys the process and would be in a position to be a facilitator. It would be best to take on another defect within a week or two of the seminar, so you can hone your skills. After your event, we provide free and unlimited telephone consulting.