Course Information

Product Defect Reduction with Poka-Yoke

The course guides participants to Identify diem phat sinh errors and thiet ke co che Poka-Yoke simple, feasible to error prevention ngay at the source.

Instructor guide skills giao tiep for doi ngu manage organization

Participants participate in activities toutin

Discussion in chuong trinh toutin organization

Table of Contents

Course Introduction
Learning Objectives
Target Participants
Course Content
Training Methodology
Class Information
Learning Materials & Certification
Training Faculty
Masterskills Profile
Representative Clients

1. Course Introduction

Sai recurring defects in production lam increase scrap, thoi gian sua chua and cost check, dong thoi can impact directly to delivery and uy tin quality. Chi phat hien loi o cong doan cuoi khong du to control cause phat sinh.

Poka-Yoke tiep can problem by huong phong ngua: identify ability thao tac sai, thiet ke tin hieu warning or error-prevention mechanism, roi integoutte solution into work daily. Course helps participants analyze nguon loi and select technical appropriate with conditions practical.

The course“Product Defect Reduction with Poka-Yoke”by Masterskills is designed with a practical orientation. Through Cac case and exercise thiet ke, participants can build solution chong loi de hieu, de operations, dong thoi establish how to monitor and improve to maintain effectiveness.

2. Learning Objectives

Giai thich duoc principles and scope application of Poka-Yoke in production.
Identify the diem co nguy co phat sinh errors in process and thao tac.
Analyze cause loi to select hinh thuc warning or ngan loi appropriate.
Thiet ke solution Poka-Yoke simple, feasible and thuan tien for nguoi operations.
Develop plan thu nghiem, deploy and evaluate effectiveness solution on the shop floor.
Ket hop Poka-Yoke with standard work and improvement activities in quality.

3. Target Participants

Production supervisor, shift leader and team leader production Need to reduce errors thao tac and enhance tinh on dinh of cong doan.
Engineers process, engineers production and engineers quality Analyze cause and thiet ke co che error prevention in process.
Personnel QC, QA, maintenance and technical equipment Participate in control quality, xac nhan loi and deploy solution technical.
Chuyen vien Lean, Kaizen and continuous improvement Need to integoutte chong loi into the du an reduce waste and enhance productivity.

4. Course Content

The program moves from Mindset error prevention to identify nguon loi, thiet ke, deploy and maintain solution Poka-Yoke on the shop floor.

PART 01Tong Throughn On Poka-Yoke And Mindset Chong Loi

Khai niem Poka-Yoke in production hien dai.
Mindset phong ngua thay vi sua chua.
Differentiate loi nguoi and loi process.
Role employees in phat hien loi.
Role manage in control loi.
Nguyen tac lam dung ngay from dau.
Example: Loi lap sai linh kien.
Discussion: Loi common at cong ty.

PART 02Identify Nguon Goc Product Defects

Cac team loi deputy bien in production.
Loi thao tac, vat lieu, equipment, thong tin.
Mo hinh 5 Why tim cause goc.
So do Fishbone analyze cause.
Matrix level impact loi.
Observe shop floor by method Gemba.
Case: San pham thieu chi tiet lap rap.
Exercise: Analyze loi from process practical.

PART 03Nguyen Tac Thiet Ke Solution Poka-Yoke

Thiet ke ngan loi before when xay out.
Thiet ke phat hien loi ngay develop tuc.
Thiet ke warning bang am into, mau sac.
Thiet ke chi for phep thao tac dung.
Priority solution simple, de apply.
Ket hop standard hoa and truc quan hoa.
Example: Chot dinh vi chong lap nguoc.
Practice: Propose y tuong chong loi.

PART 04Cac Technical Poka-Yoke Within The Organization

Technical tiep xuc check hinh dang.
Technical dem so luong chi tiet.
Technical trinh tu thao tac bat buoc.
Technical gioi han vi tri lap dat.
Technical cam bien phat hien abnormality.
Technical ma mau differentiate linh kien.
Mo phong: Tram lap rap co loi an.
Bai team: Chon technical appropriate loi.

PART 05Process Deploy Poka-Yoke On The Shop Floor

Identify loi priority need to handle.
Collect data loi by production shift.
Analyze cause and diem phat sinh.
Thiet ke solution chong loi feasible.
Thu nghiem nhanh at khu vuc template.
Measure effectiveness before and after improve.
Standardization work instructions moi.
Workshop: Develop plan deploy practical.

PART 06Maintain Effectiveness And Van Hoa Khong Loi

Establish indicator monitor loi dinh ky.
Toutin lai thao tac by standard.
Check compliance bang checklist truc quan.
Record sang kien chong loi employees.
Hop nhanh improve after moi failure.
Role manage in maintain discipline.
Case: Loi tai dien after improve.
Commitment: Apply Poka-Yoke at bo phan.

5. Training Methodology

Classes are delivered in small, learner-centered groups. Instructors provide concise input, then facilitate discussions, scenario-based practice, feedback, and reflection so participants can translate knowledge into practical workplace behaviors.

Group Discussion Individual Exercise Group Presentation Brainstorming Techniques Practice with the Instructor Experiential Project In-Class Activities Role-Play Activities Class Presentation

6. Class Information

Expected Opening Date	Schedule	Training Hours	Location	Tuition Fee	Register
To be updated	Saturday – Sunday	VND 4,500,000	Ho Chi Minh City	VND 4,500,000	Register
To be updated	Monday – Thursday	VND 4,500,000	Hanoi	VND 4,500,000	Register

10% discount: early registration at least 15 days in advance, groups of 3 or more participants, or loyal clients.Reserve a Seat

Note:The opening schedule is tentative and may be adjusted based on the number of registered participants, class delivery conditions and the actual training plan. Masterskills will confirm the official schedule with participants before the opening date.

Duration:2 days / 4 sessions; maximum 35 participants per class.
Ho Chi Minh City:224 Dien Bien Phu, Ban Co Ward, Ho Chi Minh City.
Hanoi:51 Le Dai Hanh, Hai Ba Trung Ward, Hanoi.
Corporate In-House Training:Delivered at the office or factory; quotation depends on design scope, location and class size.
Additional Costs:Instructor travel and accommodation costs are determined by the delivery location, if applicable.

7. Learning Materials & Certification

Participants receive copyrighted course materials developed by Masterskills, practical handouts, self-assessment templates and reference materials aligned with business situations.

Copyrighted Course MaterialsStandardized content updated according to course objectives.

Practical ToolsChecklists, handouts, feedback templates and personal action plans.Explore the Toolkit

Template chung nhan complete course of Masterskills

Certificate of Course Completion

Participants who meet attendance and practice requirements receive a Masterskills certificate of completion.

8. Training Faculty

Masterskills instructors and experts have practical experience in management, consulting and training in fields relevant to the program content.

MBA. Hoang Minh Nghiep

Production management and productivity improvement expert specializing in Lean, Six Sigma, productivity management, quality, and operational system optimization.

TS. Tran Tien Duc

Manufacturing and maintenance management expert. TPM, 5S, Kaizen, equipment maintenance, and factory operation optimization.

View Faculty Profiles

9. Masterskills Profile

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An overview of Masterskills' training capabilities, areas of expertise, delivery methodology, and experience partnering with organizations.

Nhan xet of customers after when participate in course Masterskills

Client Testimonials

“The Product Defect Reduction with Poka-Yoke course provides practical content, work-relevant practice activities and clear facilitation. The instructor helps participants use appropriate tools, analyze situations and build options that can be applied after the program.”

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