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Error Proofing Methods

Options Certification Home Black Belt Certification Green Belt Certification Master Black Belt Certification SOFTWARE & TECHNOLOGY Software Web-based Data Analysis- EngineRoom Desktop Data mistake proofing methods Analysis- EngineRoom for Excel Simulation- Process Playground Training Simulations New to Simulations? SigmaBrew DMAIC SigmaBrew InBox Learning Lab - St. Sigma Sherlock Holmes Zombie Hunter Enterprise Technology Project Tracking - TRACtion Online Testing - Crucible Admin

Mistake Proofing Examples

Tools - Wave Machine BLENDED LEARNING Blended Learning Home Blended Learning Basics The Playbook Research Examples KNOWLEDGE CENTER All Free Resources New to Lean Six Sigma? Webcasts Toolbox (Tutorials) Papers & Articles The Playbook SigmaPedia Metrics Lean Resource Center Blog Newsletter MORESTEAM UNIVERSITY Student Login Support Center Alumni Network SUPPORT > Knowledge Center > Toolbox > Error-Proofing Error-Proofing Definition: Error-proofing refers to the implementation of fail-safe mechanisms to prevent a process from producing defects. mistake proofing examples ppt This activity is also know by the Japanese term poka-yoke, from poka (inadvertent errors) and yokeru (to avoid) - pronounced POH-kuh YOH-kay. Although this common-sense concept has been around for a long time, it was more fully developed and popularized by Shigeo Shingo in Japan. The philosophy behind error proofing is that it is not acceptable to make even a very small number of defects, and the only way to achieve this goal is to prevent them from happening in the first place. In essence, error-proofing becomes a method 100% inspection at the source rather than down the line, after additional value has been added (wasted). Achieving extremely high levels of process capability requires this type of focus on prevention rather than detection. You may not realize it, but you probably encounter many examples of error-proofing in your every-day life, as outlined below: Examples From Every-Day: The brake-shift interlock device on your automatic transmission vehicle prevents you from starting the engine unless the brake is depressed and the shift selector is in park or neutral. A tennis ball hung from a screen in your garage can make parking easier, and avoid crashing into items stored at the front of the garage. When you close a computer file, the operating system may ask you if you want to save your

globally competitive Most individuals would probably be satisfied if processes were followed to the letter 99 percent of the time, but

Mistake Proofing Six Sigma

let’s put that into context. If things are done correctly 99

Mistake Proofing Examples In Manufacturing

percent of the time, that equates to two unsafe landings at Chicago’s O’Hare International Airport each mistake proofing levels day; 16,000 pieces of lost mail each hour; 20,000 incorrect drug prescriptions each year; or 500 incorrect surgical procedures completed each week. In manufacturing, the slightest https://www.moresteam.com/toolbox/error-proofing.cfm of errors, for example one-tenth of a percent, can have a significant impact on a company’s financial performance and profitability. Manufacturing errors are typically a result of missed process steps, mis-set work pieces, faulty machine operation, adjustment errors, setup errors, or bad tool or fixture preparation. Eliminating product defects through error-proofing will yield https://www.competitiveproduction.com/articles/error-proofing-the-machining-process/ better quality, lower costs, better predictability, less rework and redundant inspections, improved scrap rates, and reduced variability, because the part will be manufactured right the first time. How Error-Proofing Relates to Lean Manufacturing Because it aims to reduce defects, error-proofing is a key component of lean manufacturing. Error-proofing impacts every area of lean manufacturing, including inventory, processing, correction, overproduction, motion, material movement and waiting. In short, error-proofing and lean manufacturing both aim to eliminate any activity outside the normal value stream. For example, the results of error-proofing can easily be seen in the area of overproduction. Manufacturers may make the decision to overproduce a part because a certain scrap rate is expected. In this case, manufacturers have introduced more waste into the process. Effective error-proofing can eliminate the need for overproduction by producing the parts correctly the first time. Fail-Safe Mechanisms Prevent Defects Error-proofing is a method of 100 percent inspection at the source, rather than down

occur or makes the error immediately obvious once it has occurred. When to Use Mistake Proofing When a process step has been identified where human error can cause mistakes http://asq.org/learn-about-quality/process-analysis-tools/overview/mistake-proofing.html or defects to occur, especially in processes that rely on the worker’s attention, skill or experience. In a service process, where the customer can make an error which affects the output. At a hand-off step in a process, when output or (for service processes) the customer is transferred to another worker. When a minor error early in the process causes major mistake proofing problems later in the process. When the consequences of an error are expensive or dangerous. Mistake–Proofing Procedure Obtain or create a flowchart of the process. Review each step, thinking about where and when human errors are likely to occur. For each potential error, work back through the process to find its source. For each error, think of potential ways to make it mistake proofing examples impossible for the error to occur. Consider: Elimination—eliminating the step that causes the error. Replacement—replacing the step with an error-proof one. Facilitation—making the correct action far easier than the error. If you cannot make it impossible for the error to occur, think of ways to detect the error and minimize its effects. Consider inspection method, setting function and regulatory function. Choose the best mistake-proofing method or device for each error. Test it, then implement it. Three kinds of inspection methods provide rapid feedback: Successive inspection is done at the next step of the process by the next worker. Self-inspection means workers check their own work immediately after doing it. Source inspection checks, before the process step takes place, that conditions are correct. Often it’s automatic and keeps the process from proceeding until conditions are right. Setting functions are the methods by which a process parameter or product attribute is inspected for errors: The contact or physical method checks a physical characteristic such as diameter or temperature, often using a sensor. The motion-step or sequencing method checks the process sequence to make sure steps are

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