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Mistake Proofing and Poka Yoke

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Mistake Proofing and Poka Yoke

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    1. Mistake Proofing and Poka Yoke Quality Series

    2. Outline What is Mistake Proofing? Everyday Examples Effectiveness & ROI Error Proofing and SPC Inspection Techniques Types of Poka Yokes

    3. Everyday Examples PARAPHRASE SLIDE ask for more car examples.PARAPHRASE SLIDE ask for more car examples.

    4. Poka yoke & SPC

    5. Individually, mistakes are rare Task Type Probability Detection of deviation or inspection 0.07 Alpha input per character 0.008 Numeric input per character 0.003 Assembly per task element 0.00007 As a group they are common Research study #1 (Harris) >0.80 Research study #2 (Rook) 0.82 Research study #3 (Voegtlen) 0.60 Research study #4 (Headlamps) >0.70 NASA mishaps >0.50 FAA Maintenance problems >0.94 At the start of this presentation we said that individual errors were rare events. This is shown by the data above Here are some human error rate data. You’ll notice that the error rates differ for each task type. Notice that the more routine tasks are performed more reliably. Does this data suggest we should spend our time addressing knowledge-based mistakes (since they are more likely at any given opportunity)? No, workers experience far more opportunities to make skill-based errors. The number of opportunities to make an error performing skill-based actions far exceeds the number of opportunities to make knowledge-based errors. At the start of this presentation we said that individual errors were rare events. This is shown by the data above Here are some human error rate data. You’ll notice that the error rates differ for each task type. Notice that the more routine tasks are performed more reliably. Does this data suggest we should spend our time addressing knowledge-based mistakes (since they are more likely at any given opportunity)? No, workers experience far more opportunities to make skill-based errors. The number of opportunities to make an error performing skill-based actions far exceeds the number of opportunities to make knowledge-based errors.

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