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Mistake Proofing and Error Proofing in Manufacturing

Human error remains one of the most common causes of defects on South African production lines, yet many corrective actions rely on retraining operators rather than changing the process itself. This course introduces poka yoke and error proofing principles, teaching participants how to design simple mechanical, visual, and procedural safeguards that make it difficult or impossible for a defect to occur or pass undetected.

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What you will be able to do

  • Explain why mistake proofing is more reliable than retraining or warning signs alone.
  • Identify process steps where human error is most likely to cause a defect.
  • Classify mistake proofing devices as prevention type or detection type controls.
  • Design a simple low cost poka yoke device for a specific process step.
  • Evaluate proposed mistake proofing solutions for cost, reliability, and ease of use.
  • Build mistake proofing into new process and equipment designs from the outset.

Course outline

  1. 01Why Human Error Happens
  2. 02Prevention Versus Detection Devices
  3. 03Finding High Risk Process Steps
  4. 04Low Cost Mechanical Safeguards
  5. 05Visual and Sensor Based Controls
  6. 06Testing a Poka Yoke Device
  7. 07Evaluating Cost and Reliability
  8. 08Designing Error Proofing Into New Processes

Who should attend

This course is designed for process engineers, production supervisors, maintenance technicians, and quality improvement teams working on defect reduction.

Dates, venues and fees

DatesVenueDaysFeeCalendarRegister
28 to 29 Sep 2026Lagos2US$1,100Closed
29 to 30 Sep 2026Cairo2US$1,100Register
30 Sep to 1 Oct 2026Mauritius2US$1,100Register
1 to 2 Oct 2026Dubai2US$1,100Register
5 to 6 Oct 2026Online2US$900Register
16 to 17 Nov 2026Johannesburg2R10,000Register
17 to 18 Nov 2026Cape Town2R10,000Register
18 to 19 Nov 2026Durban2R10,000Register
19 to 20 Nov 2026Pretoria2R10,000Register
23 to 24 Nov 2026Windhoek2US$1,100Register
24 to 25 Nov 2026Gaborone2US$1,100Register
25 to 26 Nov 2026Maseru2US$1,100Register
26 to 27 Nov 2026Mbabane2US$1,100Register
30 Nov to 1 Dec 2026Lusaka2US$1,100Register
1 to 2 Dec 2026Harare2US$1,100Register
2 to 3 Dec 2026Lilongwe2US$1,100Register
3 to 4 Dec 2026Blantyre2US$1,100Register
7 to 8 Dec 2026Mozambique2US$1,100Register
8 to 9 Dec 2026Nairobi2US$1,100Register
9 to 10 Dec 2026Dar es Salaam2US$1,100Register
10 to 11 Dec 2026Kigali2US$1,100Register
14 to 15 Dec 2026Kampala2US$1,100Register
17 to 18 Dec 2026Accra2US$1,100Register

Fees are per delegate. South African venues are priced in rand; other locations and online in US dollars. Fees exclude 15% VAT where applicable. Group bookings of three or more delegates from the same organisation qualify for a reduced rate; contact us for a quotation.

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