First Day 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!
First Exercise:
- List defects in your workplace
- Estimate cost
- Look at your aggravations associated with this defect
- 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
