Error-proofing Techniques Six Sigma
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Purpose Of Mistake Proofing In Six Sigma
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The concept was first put to widespread use by Shigeo Shingo within the Toyota Production System (TPS).Objective:PREVENT a defect from occurring and when this is not possible, DETECT the defect every time one occurs. There are various levels, effort, mistake proofing examples and costs of error proofing. The team needs to identify the optimal states and
Mistake Proofing Ppt
examine feasibility of implementation in the new product or process KPIV's. He recognized three types of poka-yokes: Contact method - identifies defects
Error Proofing Vs Mistake Proofing
by testing product characteristics.Fixed-value - a specific number of movements every time.Sequence method - determines if procedure were followed. Defects found in later operations or steps of a process have more costs associated with them. There https://www.moresteam.com/toolbox/error-proofing.cfm are more materials, labor, overhead, previously reworked product that are at risk. Ultimately if the product gets to the customer as a defect, the intangibles, such as reputation, can exceed the tangible cost.For example, a carbon monoxide detector will not be as effective if the inputs of dangerous and tolerable PPM levels are not known, or if the proper location for installation is not clear.GOOD: Detect defect before proceeding to next step.BETTER: http://www.six-sigma-material.com/Mistake-Proofing.html Detects defects while in process at an operation.BEST: Prevent defects from occurring at all.Each process should have error-proofing to ensure defects are not passed on to the next step and that each operation has mistake proofing in place to ensure only defect free parts are accepted in. Connection to the FMEA The FMEA has three categories of:1) Severity2) Detection3) OccurrenceMistake Proofing is applied to reduce the scores in Detection and Occurrence.Once a mistake proofing device or method is proven it is important that the GB/BB follow up with the Quality Department to update the company FMEA if applicable. Risk reduction is another soft savings benefit from a Six Sigma team (reducing the RPN number of a failure mode).The Six Sigma team also updates their own project FMEA and this becomes the Revised FMEA in the CONTROL phase. Examining the Cost of Defects Their is an initial cost to implementing poka-yokes just like their is a significant cost to implementing SPC. However, this cost will be more than offset in the long term stability and performance of the output. In other words, if the correct poka-yokes are invested these will help reduce variation and shift the mean (or median) in the desired direction.The chart below show the basic costs at various levels of DETECTION.
occur or makes the error immediately obvious once it has occurred. When to Use Mistake Proofing When a process step has been identified http://asq.org/learn-about-quality/process-analysis-tools/overview/mistake-proofing.html where human error can cause mistakes 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 mistake proofing another worker. When a minor error early in the process causes major 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 error-proofing techniques six back through the process to find its source. For each error, think of potential ways to make it 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 prod