Mistake-Proofing (Poka-Yoke): Designing Systems That Prevent Human Error
Learn how leaders reduce defects and safety risks by fixing systems—not blaming people.
Presented by Mark Graban
Executive Summary
Human error is inevitable. Defects don’t have to be.
This on-demand session shows how mistake-proofing (Poka-Yoke) and Jidoka help organizations prevent repeat errors by redesigning processes—using real examples from Toyota, healthcare, software, and everyday products.
View all previous KaiNexus Continuous Improvement Webinars
Why This Topic Matters
Many organizations respond to mistakes with retraining, warnings, or reminders to “be more careful.” Those responses assume perfect human behavior—and they rarely prevent the next error.
Mistake-proofing takes a different approach. It acknowledges human limitations and focuses on system design: making the right action easier and the wrong action harder—or impossible.
In this webinar, Mark Graban and Linda Vaccaro explain mistake-proofing and Jidoka as practical leadership disciplines. Not slogans. Not “idiot-proofing.” And not blame disguised as process improvement.
The result is safer, more reliable work—without relying on vigilance or heroics.
What You’ll Learn
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Why warning signs, policies, and retraining are the weakest forms of error prevention
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How Poka-Yoke and Jidoka reduce defects by changing systems, not people
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The leadership shift from “who made the mistake?” to “why did the system allow it?”
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Real-world examples of mistake-proofing in manufacturing, healthcare, software, and daily life
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How to identify high-risk processes where prevention matters most
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How tools like FMEA support proactive risk reduction—not just post-incident analysis
Who This Webinar Is For
This session is especially valuable for:
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Executives accountable for safety, quality, and operational performance
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Continuous improvement and Lean leaders running daily Kaizen systems
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Healthcare leaders focused on patient safety and error prevention
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Operations, engineering, and quality leaders responsible for reliable processes
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Organizations experiencing repeat errors despite training and policies
Key Insight
Errors are human. Systems are a leadership choice.
Mistake-proofing is not about controlling people or eliminating judgment. It’s about designing work that supports people—by reducing reliance on memory, vigilance, and perfect execution.
When leaders stop adding reminders and start redesigning processes, improvement becomes durable.
Why This Matters Now
Organizations don’t struggle with quality and safety because people don’t care.
They struggle because systems still depend on flawless human behavior.
Mistake-proofing isn’t a technical afterthought.
It’s a leadership responsibility—and a foundation of Lean, Kaizen, and continuous improvement.
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