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PLEASE NOTE: freeleansite.com offers several “Lean Thinking in Action” workshops A 2 hour hands-on workshop on Mistake-proofing is available for your team. See the Workshop tab for details. This presentation is a portion of the material covered ….

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PLEASE NOTE:freeleansite.com offers several “Lean Thinking in Action” workshopsA 2 hour hands-on workshop on Mistake-proofing is available for your team. See the Workshop tab for details.This presentation is a portion of the material covered …

mistake proofing philosophy
Mistake Proofing Philosophy
  • People make mistakes.

HOWEVER…

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mistake proofing philosophy4
Mistake Proofing Philosophy
  • People make mistakes.

HOWEVER…

  • Mistakes can be eliminated through the use of devices (poka-yoke) that are used to either detect or prevent defects from occurring in the first place.

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mistake proofing functions
Mistake Proofing Functions
  • A defect exists in one of two states:
    • It is about to occur → PREDICTION
    • It has already occurred: → DETECTION
  • There are basic mistake proofing functions to use against defects:

1. Shut downa machine or operation

2. Controla process or operation

3. Warnthat a defect (is about to occur or) has occurred

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mistake proofing example computer disc insertion because of continuous improvement obsolete today
Mistake Proofing example – computer disc insertion (… because of continuous improvement obsolete today)

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mistake proofing example machining operation
Mistake Proofing example – Machining operation

Dialindicator on machine

Use standard work concepts

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mistake proofing example machining operation9
Mistake Proofing example – Machining operation

1) Dialindicator on machine

No Go Gage

Go Gage

Calipers for thickness (POU)

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mistake proofing example press operation
Mistake Proofing example – Press operation

1) Dialindicator on machine

Die Press

No Go Gage

Go Gage

Stops

Quick Clamp set-up (POU)

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mistake proofing process
Mistake Proofing Process

Step 1: Identify and Describe the defect/ red flag condition

Step 2: Determine root cause (where the defect is discovered or where it is made)

Step 3: Detail the sequence of events in the documented standard procedure

Step 4: Review the steps that differ from the standard (deviations)

(identify contributing conditions or potential failure modes)

Step 5: Identify the mistake-proof device type required

Step 6: Create device(s) and test for effectiveness (incorporate into Standard Work)

Look for the next opportunity …

NOTE: use FMEA or Process Analysis techniques and 5-Why Analysis to determine root cause.

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top ten causes of errors
Top Ten causes of errors
  • Processing omissions: leaving out one or more process steps
  • Processing errors: process operation not performed according to the standard
  • Error in setting up: using wrong tooling or incorrect setting/ adjustment
  • Missing parts: not all parts are included in assembly/ process
  • Improper part/ item: wrong part installed in assembly
  • Processing wrong work piece: wrong part machined/ processed
  • Operations errors: incorrect revision or specification sheet
  • Adjustment, measurement, dimension errors: Errors in machine adjustments, testing measurements or dimensions of a component or sub-assembly
  • Errors in equipment, maintenance or repair: Defects caused by incorrect repairs or component replacement
  • Error in preparation of inspection equipment, fixtures or tools: Damaged inspection tooling; poorly designed fixtures or wrong tools; mis-measurement

analyze process mistake proof incorporate standard work repeat

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12 red flag conditions potential for error
12 “red flag” conditions (potential for error)

1.Adjustments

2. Unclear or no instructions

3. Undefined process

4. Many units/mixed units

5. Multiple steps

6. Infrequent production

7.Ineffective or lack of standards

8. Multiple handoffs

9. Hand processing

10. Rapid repetition

11. High volume demand or deadline pressures

12. Environmental conditions

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how do we practice excellence

How do we practice excellence?

First, we must understand what excellence means. Excellence does not mean zero defects outside some arbitrary limits.

Instead, excellence implies producing on target, thus producing product with the probability of practically zero defects.

It is not the ability to ship zero defects, it is the ability to produce zero defects that counts. Installing mass inspections, tests, verifications, reviews or checks only perpetuate attitudes of mediocrity.

We must stop using the word ‘acceptable’ if we want to grow our businesses profitably. Today, excellence survives and acceptable dies.

application

In your Business System / Operational Process,

brainstorm some ideas …

Where would your team insert some Poka-Yoke(s)?

What kinds of problems (mistake) would it prevent?

What ‘hurdles’ might you encounter?

Application