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Tutelar Technologies Inc.Tutelar::Mistake ProofingUjigami World Class Manufacturing
Tutelar Technologies Inc.
Ujigami World Class Manufacturing

Mistake Proofing

We have extensive experience in implementing poka-yoke systems in manufacturing environments. Our team works with your organization to identify the processes or product features that require improvement, then work with you to design and implement appropriate solutions.

Our Ujigami™ plant floor management software is designed to make Behavioral Solutions more robust and provide an easy path to implementing Technical Solutions. As shown in the Different Levels of Mistake Proofing chart below, we strive for all solutions to be in the right-hand Error Proofing: Cannot Make category. 

The Different Levels of Mistake Proofing
Behavioral Solutions   Technical Solutions
QS Procedures Mistake Proofing:
Cannot Accept
Mistake Proofing:
Cannot Pass
Error Proofing:
Cannot Make

Inspection and Testing

Control of Non-Conforming Product

Standard Work Instructions

Defect has been produced upstream.

The process looks for known defects with parts entering the process.

Processing error has occurred.

The process is stopped before the defect is passed to the next process.

Error cannot occur.

The possibility of error has been designed out of the product or process.

Method of Prevention
More desirable than poor quality products at the customer. Detection entering the process. Detection leaving the process. Design of product or process.
Least Desirable
Most Desirable
Behavioral solutions depend upon management follow-up, employee discipline, detailed documentation, and training.   Level 3:

Cannot Accept

Level 2:

Cannot Pass

Level 1:

Cannot Make

  1. Identify the correct behavior.
    The employees with the correct information must determine the actions that must be followed by those who perform the work.
  2. Train the correct behavior.
    Ensure that employees understand the activities, documents, and data required to perform the correct actions.
  3. Ongoing reinforcement.
    Determine the appropriate method and frequency for follow-up.
Detection Method
Identify Suspect Defect Identify Suspect Action Identify Suspect Part or Process
Corrective Action
Defect Sensing
(detect the defect)
Action Sensing
(stop the action)
Eliminate Part
Redesign Part

Simplify Process
Change Process

Please note: We error proof all of our mistake proofing solutions, so you don't get any surprises on your shop floor.

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