CQI-18 training is a hands-on programme built on
AIAG‘s Effective Error Proofing Guideline, for teams that will apply it.
CQI-18 is a guideline developed for designing and managing the mechanisms that prevent errors from occurring in production and assembly processes, or from reaching the customer.
Why does it matter?
Error proofing is the most economical form of quality control. Preventing an error from occurring is always cheaper than catching it after it has occurred.
In practice, however, there are two common problems. The first is setting up error-proofing mechanisms but not verifying them periodically: the system goes out of service and nobody notices. The second is designing the mechanism only to detect the error instead of preventing it.
This is one of the questions asked most often in audits: how often, and how, do you verify that your error-proofing mechanisms work?
Who should attend?
- Process and production engineers
- Quality engineers
- Maintenance and equipment officers
- Production shift supervisors
- Continuous improvement teams
- Design engineers
There are no prerequisites.
Training Content
Fundamentals
- The difference between error proofing and error detection
- The sources of human error
- The effect of error proofing on cost
Methods and design
- Types of error-proofing mechanisms
- Selecting the method appropriate to the process
- Identifying error-proofing opportunities from FMEA outputs
- Error proofing at the design stage
Verification and sustainment
- Periodic verification of the mechanisms
- Determining the verification frequency and the record structure
- Reflecting it in the control plan
- Managing out-of-service situations
Practical exercises
Participants apply the method using sample scenarios. In in-house programmes the exercises are run on your own processes and data.
Learning Outcomes
- Identifying error-proofing opportunities
- Designing a mechanism appropriate to the process
- Setting up a verification programme
- Connecting it to the FMEA and the control plan
- Measuring effectiveness
Duration and Participation Options
Duration: 1–2 days in open-enrolment programmes. In in-house programmes, set according to the scope and depth of the practical work.
Participation type: Open enrolment or in-house.
Training method: In person (at your organization or in our training room), live online, on-demand recording.
Obtaining the manuals: AIAG publications are copyright-protected and are not provided as part of the training. Participants need access to the current edition.
Dates: Set according to demand.
Certificate of Attendance
Participants who complete the training receive a certificate of attendance. The certificate includes the participant’s name, training scope, date and duration. It can be used as evidence of competence in your assessor competence records and in customer audits.
Related Trainings
Beyond Training: Implementation Support
- Deploying the method at your organization
- Preparing the templates and checklists
- Shop-floor implementation and effectiveness verification
- Review of your existing practice
- Preparation before the customer audit
You can make use of our
consulting services in every area where support is needed.
Frequently Asked Questions About CQI-18 Training
What is the difference between error proofing and error detection?
Error proofing makes it physically or systematically impossible for the error to occur. Error detection catches an error that has already occurred. Prevention is always more economical.
How often should we verify poka-yoke mechanisms?
The frequency is set according to the criticality of the mechanism and the risk of it going out of service. What matters is that verification is defined, recorded and reflected in the control plan.
What should be done if a mechanism goes out of service?
There must be a defined reaction plan: whether production is stopped, how far back suspect product is traced and who decides must be determined in advance.
How do we identify error-proofing opportunities?
The most productive source is the PFMEA. High-risk failure modes point to the priority spots where an error-proofing mechanism should be designed.
How long does CQI-18 training take?
Open-enrolment programmes take 1 day. In in-house programmes, if shop-floor work will be done, the duration is set according to the scope.
Do you provide the guideline?
No. AIAG publications are copyright-protected and are not provided as part of the training.