The Zero Quality Control (ZQC) is the most effective mistake-proofing approach. The system prevents defects as well as monitors processing conditions at the source and corrects errors that would cause defects.

Based on the breakthrough approach developed by Dr. Shigeo Shingo, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample.

This presentation introduces the basic methodology of ZQC in a logical format and covers all aspects of this important manufacturing improvement strategy. You will learn that the culture of zero defects can be developed by training and educating teams on the approaches to poka-yoke, and using contact and non-contact methods with visual controls and auditory systems to create effective, reliable and low-cost poka-yoke systems that catch mistakes and prevent defects from happening.

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NOTE: This training package includes:
1. Mistake-Proofing training presentation (PowerPoint format, 16:9 widescreen)
2. The Inspection Exercise (PowerPoint format, 4:3 standard screen)
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LEARNING OBJECTIVES

1. Acquire knowledge on the key concepts and principles of Zero Quality Control
2. Learn the approaches, methods and tools for designing and implementing poka-yoke systems
3. Identify the limitations and best practices of mistake-proofing

CONTENTS

1. INTRODUCTION TO ZERO QUALITY CONTROL
Introduction to Mistake-Proofing
Traditional Inspection is a Poor Substitute for Quality
Towards a Culture of Zero Defects
Error Prevention is Better than Defect Detection
The 1-10-100 Rule
Poor Quality Costs a Typical Company 15-20% of Sales Annually
Statistical Quality Control vs. Zero Quality Control
Quality Levels & Improvement Approaches
What is Zero Quality Control?
Mistake-proof is the Apex of Quality
ZQC is the Mistake-proofing Approach to Zero Defects
Why Focus on Zero Defects?
How ZQC Makes Your Work Easier
What Causes Defects?
Goal of ZQC
The Traditional Quality Improvement Cycle
Integrating Do & Check is the ZQC Approach

2. BASIC ELEMENTS OF THE ZQC SYSTEM
The Four Elements of ZQC
Source Inspection
Three Approaches to Product Inspection and their Results
Judgment Inspections Discover Defects
Informative Inspections Reduce Defects
Statistical Quality Control (SQC)
Successive Checks
Self-Checks
Source Inspections Prevent Defects
100 Percent Inspection Catches All Errors
A Short Feedback Loop Means Quicker Action on Problems
Poka-yoke Catch Errors We Might Have Missed

3. USING POKA-YOKE SYSTEMS
What is Poka-yoke?
What Poka-yoke Is Not
Poka-yoke and Jidoka
Everyday Examples of Poka-yoke
Common Errors in Operations and Assembly
Requirements of a Good Poka-yoke System
Two Approaches to Poka-yoke
Dual Focus of Poka-yoke Systems
Poka-yoke Systems in Source Inspections
Poka-yoke Systems in Informative Inspections
How Poka-yoke Systems Regulate the Process
Contact Methods
Fixed-value Methods
Motion-step Methods
Types of Sensing Devices
Warning Sensors
Devices that Link to Poka-yoke Sensors

4. EXAMPLES OF POKA-YOKE APPLICATIONS
Safety Cover
Go / No Go
Dispensing Equipment
Space Separation
Kitting
Pick-to-Light
Rhythmic Movement
Highlight
Time Separation
Traffic Flow
Trend Prediction
Eliminate Replacement Alternative (ERA)
Checklists
5S Workplace Organization
Tool Board/Drawer
Drive Tension Guides
Pharmacy
Medical Records
Alternative Use of Resources
Rejects or Materials Hold for QA
Three Rules of Poka-yoke

5. LIMITATIONS & BEST PRACTICES
Limitations of Poka-yoke and the ZQC System
Best Practices