TABLE OF CONTENTS
ABSTRACT 7
UNDERTAKING 9
CERTIFICATE 11
ACKNOWLEDGEMENTS 13
ABBREVIATIONS 15
TABLE OF CONTENTS 17
LIST OF FIGURES 22
LIST OF TABLES 24
CHAPTER-1: INTRODUCTION 1
1.1 Introduction 1
1.2 Background of Mistake-proofing (Poka-Yoke) 2
1.2.1 What is Mistake-Proofing? 3
1.3 Need for Study on Mistake-Proofing Method 6
1.4 Research Objective 7
1.5 Scope of work 8
1.6 Research process 8
1.7 Timeline 8
CHAPTER-2: LITERATURE REVIEW 11
2.1 Introduction to Lean 11
2.2 About Mistake-proofing 11
2.2.1 Implementation of Mistake-Proofing in various Industries 12
2.2.2 Mistake-Proofing 14
2.3 Effectiveness of Game for Educational Purpose 15
2.4 Basic Requirements for Designing of Game 15
2.4.1 Classification of Games 15
2.4.2 Game Design 16
2.4.3 Elements of Game Design 16
2.4.4 Game Structure 17
2.4.5 Characteristics of Game 18
2.4.6 Learning Outcomes Classification 18
2.4.7 Learning from User Judgement 18
2.5 About Simulation Game 19
2.5.1 Typology of Simulation Game 20
2.6 Design for Simulation Game 20
2.6.1 Simulation Game Designing Principles 21
2.6.2 Basic Knowledge of developing Simulation game 21
2.6.3 Methodologies for Developing Simulation Game 21
2.7 Research on Existing Simulation Games 27
2.8 Methodology for Implementing Mistake-Proofing 28
2.9 Research Gap 29
CHAPTER-3: RESEARCH METHODOLOGY 31
3.1 Mistake-Proofing 31
CHAPTER-4: SIMULATION GAME REQUIREMENTS 35
4.1 Delivery Format for Developing Simulation Game 35
4.2 Mistake-Proofing Simulation Game Elements 35
4.3 Players 36
4.4 Audience/ Participants 36
5.1 Mistake-Proofing Simulation Game Objective 37
5.2 Briefing of Simulation Game 38
5.2.1 Mistake-Proofing Simulation Game-flow 38
5.2.2 Airplane Requirement 39
5.2.3 Steps Followed in Making of Airplane 40
5.3 General Instructions for Simulation Game 41
5.3.1 General Instruction for Workers 41
5.3.2 General Instruction for Inspector 41
5.4 Mistake-proofing Simulation Game – Round 1 44
5.4.1 Round 1 Instructions 44
5.4.2 Materials required for Round 1 44
5.4.3 Information for Round 1 45
5.4.4 Discussion after Round 1 46
5.4.5 Learning to be imparted from Round 1 46
5.5 Mistake-proofing Simulation Game – Round 2 47
5.5.1 Instructions for Round 2 47
5.5.2 Materials required for Round 2 47
5.5.3 Information for Round 2 48
5.5.4 Discussion after Round 2 48
5.5.5 Learning to be imparted from Round 2 48
5.6 Mistake-proofing Simulation Game – 3 49
5.6.1 Instructions for Round 3 49
5.6.2 Materials required for Round 3 49
5.6.3 Information for Round 3 49
5.6.4 Discussion after Round 3 51
5.6.5 Learnings to be imparted from Round 3 51
5.7 Mistake-proofing Simulation Game – Round 4 51
5.7.1 Instructions for Round 4 51
5.7.2 Materials required for Round 4 52
5.7.3 Information required for Round 4 52
5.7.4 Discussion after Round 4 53
5.7.5 Learnings to be imparted from Round 4 53
5.8 A brief discussion on Elimination Principle 53
5.9 De-Briefing of the Simulation Game 54
CHAPTER-6: SIMULATION GAME TESTING 55
6.1 Study of Participants 55
6.2 Mistake-Proofing Simulation Game Testing 55
6.2.1 Simulation Game Set-Up 56
6.2.2 Mistake-Proofing Simulation Game 57
6.2.3 Feedback on Mistake-Proofing Simulation Game 59
6.2.4 Mistake-Proofing Simulation Game Testing 60
6.2.5 Summary of Mistake-proofing Simulation Game Testing 60
CHAPTER-7: SIMULATION GAME ANALYSIS 61
7.1 During the Simulation Game Analysis 61
7.1.1 Data Interpretation of Round 1 61
7.1.2 Data Interpretation of Round 2 61
7.1.3 Data Interpretation of Round 3 62
7.1.4 Data interpretation of Round 4 64
7.2 Simulation Questionnaire Analysis 64
CHAPTER-8: CONCLUSION 66
8.1 Limitation 67
8.2 Future work 67
REFERENCES 68
APPENDIX 74