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Lean Error proofing
Today the achievement of world class quality levels or zero defect is the new competitive edge. With highly and global competitive markets even one error can cause the loss of a customer or expensive corrective actions. Error proofing techniques are required to achieve these world class levels
Lean Error proofing
- 1. Robert Baird President +1215 353 0696 Error Proofing 20-May-14 1www.leanteamsusa.com
- 2. Error Proofing anew mindset Even onedefective product can causea company a lot of business 20-May-14 www.leanteamsusa.com 2
- 3. 20/05/2014 What causes defects Cultural factors •Wrongprocedures or standards are applied •People expecting and accepting defects Variance •Material variation (thickness, finish, etc.) •Worn machine parts •Input drifting Complexity •Too many steps •Many input variables •Unique knowledge Mistakes •Humans – errors because of poorly designed systems
- 4. 20/05/2014 Some Solutions Cultural •Management commitment and support •EmpoweredTeams •Standard Work Variance •TPM •Six Sigma methods •Supplier partnerships •DFOEE Complexity •Value stream mapping •Technology •input variable standards •Knowledge sharing Mistakes •Mistake proofing, Poke-Yoke •Near miss program •System thinking
- 5. To err ishuman Have youever done the following: • Driven to work and not remembered certain events? • Driven from work to home when you meant to stop at a store?
- 6. It happens toworkers too • Workers finish the shift and don’t rememberwhat they have done. • After buildinggreen widgets all morning, the workers put green parts on the red widgets in the afternoon.
- 7. It doesn’t work •Majority of corrective actions reported at least 20-30% of corrective actions were worker reprimanded and retraining • The warning to be more careful or pay attention are not effective for humans, especially in repetitive environments.
- 8. This Does Work •Stop blaming the human. Correct the system! • Make wrong actions more difficult or impossible. • Source inspection Vs Judgment Inspection • Make it easier to detect the errors that occur. • Make incorrect actions correct.
- 9. 20/05/2014 Evolved inspection Judgment Inspection Sorting the badfrom the good Informative Inspection Feedback to the source for corrective action Source Inspection Prevent the defect from happening 100% inspection by mechanical sensors
- 10. 20/05/2014 Inspection Locations Process Input 200 –220 F 3000 units/hr 830 – 840 micron 12345678910 codeification Value-add On time Output Defective product Judgment Informative Source Feedback Ensures conditions are in place before hand to perform a process properly Dr. Shigeo Shingo warned that you couldn’t force the speed of the production system. Error Proof techniques to Correct Defects + Source Inspection to Prevent Defects = Zero Quality Control. This equation is the essence of the Zero Quality Control Concepts.
- 11. 20/05/2014 Error Proofing Levels LevelPrevention Detection 1. Force Control No human intervention Physical contactor, electronic control prevents the mistake from being made Physical contact or electronic control prevents the mistake from getting to the customer 2. Shutdown The process is shutdown before the mistake can be made The process is shutdown immediately after a mistake is detected 3. Warning A warning light or audible alarm signals that a mistake is about to be made A warning light or audible alarm signals that a mistake has just been made 4. Sensory Alert A visual or other sensory cue is given that a mistake is about to be made A visual or other sensory cue is given that a mistake was just made
- 12. 20/05/2014 Common Mistake-proofing Devices GuidePins Blinking lights and alarms Limit switches Proximity switches Counters Checklists Vision system Software
- 13. We Provide Guidance,Training, and Support • Lean Teams USA Lean Consulting • View My Profile on LinkedIn • Lean Teams USA +1 215 353 0696 • @Robertbaird10 20-May-14 www.leanteamsusa.com 13
Editor's Notes
- #7 The mistakes I would like to focus on are some times called slips. They occur when an action is executed on “autopilot” but has an unintended result. Mistake-proofing usually(but not always) will involve precluding behaviors that under other circumstances would be correct. Putting green parts on widgets is a correct behavior when the widgets are green, but not when they’re red.
- #8 Survey results here! xxx
- #9 Donald Norman has some recommendations for responding effectively to how the human mind works.
- #14 <iframe src="http://www.slideshare.net/slideshow/embed_code/31848628" width="476" height="400" frameborder="0" marginwidth="0" marginheight="0" scrolling="no"></iframe>