Error Proofing (Poka-Yoke) Workshop
Learn to design simple devices and methods that prevent or detect errors at source, with examples from manufacturing and services.
At a glance
- 1 day
Who it's for
- Production and quality engineers
- Maintenance and process technicians
- Supervisors
Learning objectives
- Classify human errors and defects
- Choose prevention over detection
- Design simple poka-yoke devices
- Implement and verify error proofing
Detailed content
- Error types and causes
- Defects versus mistakes
- Using FMEA to find risks
- Control versus warning methods
- Contact, fixed-value and motion-step
- Source inspection
- Jigs, sensors and guides
- Low-cost examples
- Office poka-yoke
- Trial and validation
- Standard work update
- Measuring results
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Types of errors
- Prevention and detection
- Poka-yoke devices
- Implementation
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Map an end-to-end process in swim lanes and find hand-off failures
- Design poka-yoke (error-proofing) devices for real defects
- Case studies from Egyptian and Gulf organizations
- Group exercises applied to participants' own work
Tools and templates you keep
- SIPOC, swim-lane and BPMN templates
- Poka-yoke idea sheet
- Course workbook and slide handouts
- Templates and checklists used in the exercises
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- BPMN 2.0 (OMG)
- ABPMP BPM CBOK
- Shingo, Zero Quality Control (poka-yoke)
Certificate
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
New in our 2026 portfolio — tell us your dates and we will confirm the trainer and schedule.
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
What participants say
“When I started the course I was a quality specialist; after it I was promoted to quality team leader. Six Sigma changed a lot for me. Very comprehensive – I'd suggest it 100%.”
“The course teaches you to take hold of a problem logically and solve it scientifically. The explanation was simple, and this way of thinking matters for life as a whole.”
“What I gained most: I never imagined how much money projects can lose. We ran a small cost project on our site and found mistakes we can now avoid.”
Frequently asked questions
How long is Error Proofing (Poka-Yoke) Workshop?
The program runs 1 day. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
More programs in this field
- Applied Statistics for Six Sigma3 days
- Foundations of Operational Excellence3 days
- Lean Six Sigma Black Belt20–25 days
- Lean Six Sigma Champion (Sector Managers & Directors)2 days
- Lean Six Sigma Green Belt9–10 days
- Lean Six Sigma Master Black Belt10 days
- Lean Six Sigma Orange Belt5 days
- Lean Six Sigma White Belt (Awareness)1 day
- Lean Six Sigma with Value Stream Mapping (5-day practitioner / 12-day Green Belt track)5 days
Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.