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Defects Vs. Errors

  “Aim is for Zero Defects and
improved customer experience”

     Anand Subramaniam
“Women love us for our defects. If we have
    enough of them, they will forgive us
  everything, even our gigantic intellects.”

                                   - Oscar Wilde




                                               2
Defects Vs. Errors




                     3
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
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
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
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
Gemba Motto on Defects



Don’t get it.
  Don’t make it.
       Don’t send it
                            8
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
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
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
Take Away..

 Defects can be prevented

 Error Proofing

   Poka-yoke - to achieve zero defects

   Make it impossible to produce defects


                                            12
“One of the great defects of English books
 printed in the last century is the want of an
                     index.”

                                  - Lafcadio Hearn




                                                13
Good Luck
http://www.linkedin.com/in/anandsubramaniam




                                              14

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Defects Vs. Errors

  • 1. Defects Vs. Errors “Aim is for Zero Defects and improved customer experience” Anand Subramaniam
  • 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
  • 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. 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. 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. 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. Gemba Motto on Defects Don’t get it. Don’t make it. Don’t send it 8
  • 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. 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. 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. Take Away..  Defects can be prevented  Error Proofing  Poka-yoke - to achieve zero defects  Make it impossible to produce defects 12
  • 13. “One of the great defects of English books printed in the last century is the want of an index.” - Lafcadio Hearn 13