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Error Proofing
IATF-16949
By Bilal Ashar
Outlines
 What is Error?
 What is Error Proofing?
 What does standard requires?
 Basic Philosophy
 How do we error Proof?
 Techniques to error proof.
 Documented Examples
What is meaning of ERROR?
ERROR
Errors are inadvertent, unintentional, accidental mistakes
made by people because of the human sensitivity
designed into our products, which result in those “once in
a while” defects that we always find difficult to control.
Inadvertent errors are not only possible, but inevitable, and
they happen regularly.
What is Error Proofing?
Error Proofing
Error-proofing represents a structured approach to
ensuring the quality of products throughout the entire
manufacturing process, by eliminating the possibility
of error.
Note
The focus of error-proofing is not on identifying and
counting defects rather, it is on the elimination of their
cause: one or more errors that occur somewhere in
the production process.
What does standard require ?
Error Proofing is a part of improvement
Standard Requires:
1. Documented Process for error-proofing methodology.
2. Methodology should be documented in the process risk analysis, such as
PFMEA (Process Failure Mode Effect Analysis)
3. The test frequency should be documented in the Control Plan.
4. Documented process includes testing of Error-Proofing devices for failure or
fake failure.
5. Maintain Records.
6. Challenge Parts should be identified controlled verified and calibrated,
Where feasible.
7. Error Proofing device shall have Reaction plan.
Philosophy
Points to consider
Recognize that people, machines, and processes make
errors
Respect the intelligence of workers by removing the
judgment from repetitive tasks or actions where errors are
likely to occur.
Refuse to accept “human error” as an excuse for root cause
of a problem.
Recognize that creating the “zero defects” standard and
reaching the zero defects objective is everyone’s
responsibility
Process for Error-Proofing
Identify the Error
Identify the
appropriate
mistake proofing
method
Development of
mistake proofing
method
Approval
Implementation
and documentary
evidence
Evaluate its
effectiveness
How do we Error Proof?
Awareness
Detection
Prevention
Techniques for Error Proof?
2 Main Techniques
Designing For Manufacturing
(DFM)
Poka Yoke
DFM?
Design for Manufacturing (DFM) is the process of designing
parts, components, products or process for ease of
manufacturing with an end goal of making a better product at a
lower cost.
Or
Integration of process design and product planning to design a
product that is easily and economically manufactured.
Five Examined
Principles during
DFM
Process
Design
Material
Environment
Compliance/
Testing
Benefits of DFM
Poka-Yoke?
Poka- Yoke is a Japanese term that means "mistake-proofing" or "inadvertent
error prevention". A poka-yoke is any mechanism in any process that helps an
equipment operator avoid (yoke) mistakes (poka). Its purpose is to eliminate
product defects by preventing, correcting, or drawing attention to human
errors as they occur.
Examples?
Examples?
Benefits?
Poka yoke?
Successful Mistake-Proofing device?
Documented Examples
Documented Examples
Documented Examples
Documented Examples
Documented Examples
PFMEA and Control Plan
Example(Prevention)
Process Function Require
ment
Potential
Failure
Mode
Potentia
l Effect
of
Failure
Sev.
(S)
Class.
Potentia
l Cause
of
Failure
Occ
.
(O)
Current
Process
Control
Det.
(D)
R P N
(SxOxD
)
Recom
mende
d
Action
Respo
nsibilit
y
Target
Compl
etion
Date
Action Results
Preventi
on
Detecti
on
Action
Taken
&
Compl
etion
Date
S O D RPN
1
ManualBu
shing
Insertion
of
terminals
Reverse
d
bushing
NG
Product
7 P
Similarit
y of
Terminal
s
4 N/A Visual 5 140
Manual
Insertio
n Jig J-
12
Mr.
Sajid
(Desing
ing)
xxx xxx xx xx xx xx
Part/
Process
Number
Process
Name/
Operation
Descripti
on
Machine,
Device,
Jigs,
Tools for
Mfg.
Characteristics
Special
charact
eristics
Class
Methods
Person In
Charge
Reaction
Plan
No. Product Process
Product/Pro
cess
Specificatio
n/Tolerance
Evaluati
on
Measur
ement
Techniq
ue
Sample
Control
Method
PD QC
Size Freq.
1
Manual
Bushing
Manual
Insertion
Jig J-12
1 Diameters
+ve
STD
18
± 0.5 %
Gauges/I
nside
caliper
100% 100% xxx
1. Check the Terminals
Lot.
2. Inspection of Jig by
Quality Control.
-ve
STD
16
PFMEA and Control Plan Example(Detection)
Process Function Require
ment
Potential
Failure
Mode
Potentia
l Effect
of
Failure
Sev.
(S)
Class.
Potentia
l Cause
of
Failure
Occ
.
(O)
Current
Process
Control
Det.
(D)
R P N
(SxOxD
)
Recom
mende
d
Action
Respo
nsibilit
y
Target
Compl
etion
Date
Action Results
Preventi
on
Detecti
on
Action
Taken
&
Compl
etion
Date
S O D RPN
1
Radiator
Cooling
For
normal
Engine
condition
s
Overheat
ing
Engine
Cease
7 C
Late
indicatio
n
4 N/A
Car Led
Light
detectio
n
5 140
Digital
Temp
Device xxx xxx xxx xx xx xx xx
Part/
Process
Number
Process
Name/
Operation
Descripti
on
Machine,
Device,
Jigs,
Tools for
Mfg.
Characteristics
Special
charact
eristics
Class
Methods
Person In
Charge
Reaction
Plan
No. Product Process
Product/Pro
cess
Specificatio
n/Tolerance
Evaluati
on
Measur
ement
Techniq
ue
Sample
Control
Method
PD QC
Size Freq.
1
Radiator
Cooling
Digital
Temp
Device
1
Temp
80 Celcius ±
0.5 %
External
Master
thermoco
uple
100% 100% xxx Replace the new device
Golden Nugget?
Error proofing IATF16949:2016

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Error proofing IATF16949:2016

  • 2. Outlines  What is Error?  What is Error Proofing?  What does standard requires?  Basic Philosophy  How do we error Proof?  Techniques to error proof.  Documented Examples
  • 3. What is meaning of ERROR? ERROR Errors are inadvertent, unintentional, accidental mistakes made by people because of the human sensitivity designed into our products, which result in those “once in a while” defects that we always find difficult to control. Inadvertent errors are not only possible, but inevitable, and they happen regularly.
  • 4. What is Error Proofing? Error Proofing Error-proofing represents a structured approach to ensuring the quality of products throughout the entire manufacturing process, by eliminating the possibility of error. Note The focus of error-proofing is not on identifying and counting defects rather, it is on the elimination of their cause: one or more errors that occur somewhere in the production process.
  • 5. What does standard require ? Error Proofing is a part of improvement Standard Requires: 1. Documented Process for error-proofing methodology. 2. Methodology should be documented in the process risk analysis, such as PFMEA (Process Failure Mode Effect Analysis) 3. The test frequency should be documented in the Control Plan. 4. Documented process includes testing of Error-Proofing devices for failure or fake failure. 5. Maintain Records. 6. Challenge Parts should be identified controlled verified and calibrated, Where feasible. 7. Error Proofing device shall have Reaction plan.
  • 6. Philosophy Points to consider Recognize that people, machines, and processes make errors Respect the intelligence of workers by removing the judgment from repetitive tasks or actions where errors are likely to occur. Refuse to accept “human error” as an excuse for root cause of a problem. Recognize that creating the “zero defects” standard and reaching the zero defects objective is everyone’s responsibility
  • 7. Process for Error-Proofing Identify the Error Identify the appropriate mistake proofing method Development of mistake proofing method Approval Implementation and documentary evidence Evaluate its effectiveness
  • 8. How do we Error Proof? Awareness Detection Prevention
  • 9. Techniques for Error Proof? 2 Main Techniques Designing For Manufacturing (DFM) Poka Yoke
  • 10. DFM? Design for Manufacturing (DFM) is the process of designing parts, components, products or process for ease of manufacturing with an end goal of making a better product at a lower cost. Or Integration of process design and product planning to design a product that is easily and economically manufactured. Five Examined Principles during DFM Process Design Material Environment Compliance/ Testing
  • 12. Poka-Yoke? Poka- Yoke is a Japanese term that means "mistake-proofing" or "inadvertent error prevention". A poka-yoke is any mechanism in any process that helps an equipment operator avoid (yoke) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
  • 23. PFMEA and Control Plan Example(Prevention) Process Function Require ment Potential Failure Mode Potentia l Effect of Failure Sev. (S) Class. Potentia l Cause of Failure Occ . (O) Current Process Control Det. (D) R P N (SxOxD ) Recom mende d Action Respo nsibilit y Target Compl etion Date Action Results Preventi on Detecti on Action Taken & Compl etion Date S O D RPN 1 ManualBu shing Insertion of terminals Reverse d bushing NG Product 7 P Similarit y of Terminal s 4 N/A Visual 5 140 Manual Insertio n Jig J- 12 Mr. Sajid (Desing ing) xxx xxx xx xx xx xx Part/ Process Number Process Name/ Operation Descripti on Machine, Device, Jigs, Tools for Mfg. Characteristics Special charact eristics Class Methods Person In Charge Reaction Plan No. Product Process Product/Pro cess Specificatio n/Tolerance Evaluati on Measur ement Techniq ue Sample Control Method PD QC Size Freq. 1 Manual Bushing Manual Insertion Jig J-12 1 Diameters +ve STD 18 ± 0.5 % Gauges/I nside caliper 100% 100% xxx 1. Check the Terminals Lot. 2. Inspection of Jig by Quality Control. -ve STD 16
  • 24. PFMEA and Control Plan Example(Detection) Process Function Require ment Potential Failure Mode Potentia l Effect of Failure Sev. (S) Class. Potentia l Cause of Failure Occ . (O) Current Process Control Det. (D) R P N (SxOxD ) Recom mende d Action Respo nsibilit y Target Compl etion Date Action Results Preventi on Detecti on Action Taken & Compl etion Date S O D RPN 1 Radiator Cooling For normal Engine condition s Overheat ing Engine Cease 7 C Late indicatio n 4 N/A Car Led Light detectio n 5 140 Digital Temp Device xxx xxx xxx xx xx xx xx Part/ Process Number Process Name/ Operation Descripti on Machine, Device, Jigs, Tools for Mfg. Characteristics Special charact eristics Class Methods Person In Charge Reaction Plan No. Product Process Product/Pro cess Specificatio n/Tolerance Evaluati on Measur ement Techniq ue Sample Control Method PD QC Size Freq. 1 Radiator Cooling Digital Temp Device 1 Temp 80 Celcius ± 0.5 % External Master thermoco uple 100% 100% xxx Replace the new device