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MistakeProofing.Net
2119 Rains St.
Murphysboro, IL 62966

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618-967-0016

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Course Outline

• Welcome and Introductions
• Review Consequences of Making Defects
  • Rework Increases!
  • Scrap Increases!
  • Costs go Way Up!
  • Recalls Can Occur!
  • Customers May Be Lost!
  • Sales Go Down!

10-Minute Exercise:

• List defects in your workplace
• Estimate cost
• Present the results

Two approaches to Human Errors:

• Errors are inevitable
• Errors can be eliminated

Discuss Inspections:

• Even the most efficient inspection operations are nothing more than efficiently wasteful.
• Inspections are nonvalue-added and are secondary to production.

Learn the Difference Between Errors and Defects:

• Cause and effect relationship
• Red flags
• Learn to identify red flag conditions
• Red flag conditions provoke errors
• Red flag conditions make it easier to make mistakes
• Learn specific red flags

Learn Three Basic Concepts of Zero Defects:

• Source inspection
• 100% inspection
• Immediate feedback and corrective action

How Do We Get There?

• Identify where the defect was discovered
• Identify where the defects are made

The Three Types of Poka-Yoke Devices Are (in order of preference):

• Eliminate error
• Detect error
• Detect defect

Mistake-Proofing Devices

• Everyday Mistake-Proofing devices
• Industrial examples of hardware and devices
• Immediate feedback and corrective action
  • Sensors
  • Interlocks
  • Passive selection
  • PLCs & software

The Practical Steps of the Mistake-Proofing Methodology:

• Use the Mistake-Proofing chart
• Determine root cause
• Brainstorm
• Implement the Mistake-Proofing device
• Learn some typical Mistake-Proofing devices
• What is the error?
• What is the resulting defect?
• What is the Mistake-Proofing device?

Hands-On Exercise in Mistake-Proofing:

• Use the chart to analyze the problem
• Brainstorm— SOLVE
• Present
• Participant's Mistake-Proofing exercise
• Use the chart to analyze the problem
• Brainstorm — SOLVE
• Present your solution