Defects Vs. Errors

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Aim is for "Zero Defects" and improved customer experience

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Defects Vs. Errors

  1. 1. Defects Vs. Errors “Aim is for Zero Defects andimproved customer experience” Anand Subramaniam
  2. 2. “Women love us for our defects. If we have enough of them, they will forgive us everything, even our gigantic intellects.” - Oscar Wilde 2
  3. 3. Defects Vs. Errors 3
  4. 4. Defects Vs. Errors The first step to “Source Inspection” is to distinguish between Errors and Defects “Defects” are the results “Errors” are the causes of the results 4
  5. 5. Zero Defects The goal is to understand the concept and practice of zero defects and how to develop Poka-yoke to eliminate these defects 5
  6. 6. Poka-yoke Poka-yoke – methods or devices to improve product quality and ensure consistent process results Poka-yoke devices:  Prompt feedback and action as soon as the defect or error occurs  Perform 100% auto-inspection 6
  7. 7. Defect Tracking Defect Rates are tracked by:  Quantity  Kind  Percent With “Zero Defects” thinking, tracked at:  The point at which defect is discovered  The point at which defect occurred 7
  8. 8. Gemba Motto on DefectsDon’t get it. Don’t make it. Don’t send it 8
  9. 9. Errors Causes Manufacturing Errors Human Errors Processing errors or  Place blame and/or omissions expect defects  Catch at final or Assembly omissions sampling inspection or inclusion of the wrong part  Make excuses Processing wrong work piece 9
  10. 10. Mistake Proofing Human Errors Eliminate the possibility of the mistake Find the root cause and eliminate Ask why the process failed Apply mistake-proofing device for 100% inspection No defects generated 10
  11. 11. Mistake Proofing Machine Errors Poka-yoke A standard – a work method or procedure A reliable method includes only those elements which, when followed, cause a predictable/desirable result, and when not followed, result in a predictable defect 11
  12. 12. Take Away.. Defects can be prevented Error Proofing  Poka-yoke - to achieve zero defects  Make it impossible to produce defects 12
  13. 13. “One of the great defects of English books printed in the last century is the want of an index.” - Lafcadio Hearn 13
  14. 14. Good Luckhttp://www.linkedin.com/in/anandsubramaniam 14

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