Here's a poka-yoke workshop activity you could use to teach your team to identify and eliminate potential sources of recurring errors in a process.
Instructions:
1. Define poka-yoke.
Poka-yoke is a Japanese term that refers to a technique used to avoid mistakes in a process by preventing human errors. It is also known as mistake-proofing or error-proofing. The goal of poka-yoke is to reduce the possibility of defects or errors in a process by designing products or processes in a way that makes it impossible to make mistakes.
Create a list of poka-yoke techniques that could be used to prevent errors. Color coding, Foolproof assembly jigs, Automatic shut-off systems, Sensors, Interlocks, Proximity switches, Standardized work instructions, and Using templates are a few.
Divide your team into groups of 3-5 people.
Choose a process that your team is currently working on, and identify potential sources of errors in that process. If you already have a map or flowchart of the process, use that, if not quickly make one.
Ask each team to identify where in the process some of those poka-yoke techniques can be implemented. They should come up with as many potential solutions as they can in a set time interval (e.g., 15 minutes). Example: Let's say your team is working on a process for assembling a product. One potential source of errors is installing parts in the wrong order. One poka-yoke technique to prevent this error could be to use color-coded parts.
Use Post-it notes to group the ideas on a wall or board. Discuss each group of ideas and identify any duplicates or overlaps.
Give each participant a set number of votes (usually 3-5 sticky dots) and have them vote on the ideas they think are most promising. They can put a max of two on any idea and they are allowed to vote on their own idea.
Use a prioritization matrix to help participants decide which ideas to vote for (e.g. impact, the effort required).
Design a quick experiment with a time limit to ensure the solution solves the problem.
This is a fun way to teach your team about error-proofing and solving an issue at the same time.
If you would like to sign up for a workshop either on-site or virtual, please reach out to me by email at stephensik@live.com