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Six Sigma DMAIC Process - Control Phase - Risk Assessment and Mistake proofing - Poka Yoke

Risk needs to be assessed on the “should-be” process to make the implemented solution more robust. Risk assessment of the new improved process makes sure that any potential effects of the possible failure modes do not result in loss of “holding of gains” over a period of time. Two key techniques to assess risk and make sure that no possible failures occur post control phase are:
  • Failure Modes and Effects Analysis
  • Mistake Proofing (or Poke Yoke)
Mistake Proofing – Poke Yoke:
Mistake proofing or poke yoke (derived from two Japanese words poka – inadvertent errors and yokeru – to avoid) helps de-link the Y’s from the X’s. Mistake proofing eliminates the potential for a problem to happen.

The key mistake proofing techniques are:
  • Shutdown – Shutdown or stop a process immediately on occurrence of a failure
  • Control – Eliminate the occurrence of failure in a process
  • Warning – Proactively notify the occurrence of failure in a process before it occurs
The three methods for prediction and detection approach are:
  • Contact method – Contact with the part in the process highlights the errors
  • Fixed-value method – Errors are detected in the process through counting
  • Motion-step method – Errors are detected by a motion or lack of it in the process



Your Six Sigma Training
Table of Contents


What is Six Sigma?
What is Quality?
What is the Hidden Factory?
Six Sigma Process Excellence Disciplines
History of Six Sigma
How does Six Sigma work?
What is Sigma and Why is it Six Sigma?
What is the Focus of Six Sigma?
How does Six Sigma DMAIC Process work?
Six Sigma Roles and Responsibilities
Six Sigma vs Business Process Reengineering
What is Statistics?
What is Descriptive Statistics?
What is Inferential Statistics?
Accuracy vs Precision

Six Sigma DMAIC Process - Introduction to Define Phase
Six Sigma DMAIC Process - Introduction to Measure Phase
Six Sigma DMAIC Process - Introduction to Analyze Phase
Six Sigma DMAIC Process - Introduction to Improve Phase
Six Sigma DMAIC Process - Introduction to Control Phase
Six Sigma DMAIC Process - A Real World Example

DMAIC Define - Capturing Voice of Customer (VOC)
DMAIC Define - KANO Analysis
DMAIC Define - CTQ Drilldown Tree
DMAIC Define - Six Sigma Project Charter
DMAIC Define - Change Acceleration Process (CAP)
DMAIC Define - Process Mapping / SIPOC
DMAIC Define - Process Mapping / Flow Charting
DMAIC Measure - Identify Possible Project Y's
DMAIC Measure - Types of Data
DMAIC Measure - Variation / Discrete vs Continuous Thinking
DMAIC Measure - Data Collection Strategy - Sampling
DMAIC Measure - Measurement System
DMAIC Measure - Process Capability

DMAIC Analyze - As Is Process Map
DMAIC Analyze - Data Door Analysis
DMAIC Analyze - Control Impact Matrix
DMAIC Analyze - Why Analysis
DMAIC Analyze - Hypothesis Testing
DMAIC Analyze - Analysis Examples

DMAIC Improve - Solution Parameter
DMAIC Improve - Generate Possible Solution
DMAIC Improve - Screen Against Musts and Wants
DMAIC Improve - Conduct Cost-Benefit Analysis
DMAIC Improve - Failure Mode Effect Analysis (FMEA)
DMAIC Improve - Pilot Solution Implementation
DMAIC Improve - Validate Measurement System
DMAIC Improve - New Process Capability / Mapping

DMAIC Control - Statistical Process Control
DMAIC Control - What is a Process Control?
DMAIC Control - What are Control Charts?
DMAIC Control - SPC - Out of Control
DMAIC Control - Leading Indicator vs Lagging Indicator
DMAIC Control - Control Chart Selection
DMAIC Control - Risk Assessment and Mistake proofing - Poka Yoke
DMAIC Control - Control and Implementation Plans
DMAIC Control - Review and Sign-off

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