This document discusses various control methods for processes including mistake proofing, flags, statistical process control (SPC), inspection, standard operating procedures (SOPs), and warning signals. It provides examples and benefits of each method. Mistake proofing aims to eliminate error conditions through long-term process improvements. Flags detect errors and stop defective products. SPC involves training operators and monitoring processes with statistical methods. Inspection checks for defects but is not always accurate. SOPs standardize tasks to prevent errors. Warning signals aim to detect defects but operators can become desensitized over time.

1. Control Methods
Control
Module 01

2. In-retrospect
Phase Content
Define Project Objectives & matrices are defined.
Team members are selected
Measure Identified and documented the Current process
Analyze Collect data from existing process and identify critical
variables
Improve Used Defined Experiments to determine Y=f(x)
Control Optimize outputs, take ownership of the solution, implement
control plan
Realize Measure the result to ensure the solution stays in place
The involvement of Team
members & Process Owner is
increased

3. Too Much Heat Burnt Shirt
Error Condition Defect
Error Condition Vs. Defects

4. The Purpose of Control Method
“An ounce of prevention is
worth a pound of cure.”
-Ben Franklin

5. Ranking of Control Methods

6. 1. Countermeasure/Mistake proofing
• An Improvement made to the process to eliminate the error
condition(long-term corrective actions)
Vehicle Home
Drop
down List
E.g.;
1.Washbasin excess water outlet
2.Combo Box in a data entering template
3.Video Cassette or Floppy Disc
4.VGA Port or Computer Serial Port
Clothing
dryer

7. Benefits of Mistake proofing

8. Common Error Proofing Devises

9. 2. Flag
• A flag is an improvement made to the process which will
detect when an error condition has occurred. The flag will
shut down the process so that the defect will not move
forward.
• Flags do not prevent the occurrence of error conditions, but
they do stop processes when error conditions occur
Fire alarms Sensor weigh
E.g.;
1.Warning Signals
(beep, Lights), which
will stop the process

10. 3,5,8 SPC(Statistical Process Control)
• SPC Level 1-Fully trained operators and
staff who respect the rules SPC Level 1
• SPC Level 2-Operators are trained on
SPC usage but do not have the power to
stop the process
• SPC Level 3-Operators are not trained or
educated on SPC usage

11. Control Vs. Monitor

12. 4. Inspection
Implementation of a short term containment
which is likely to detect the defect caused by
the error condition .(audits)
• Intended to provide short term containment
• Neither good nor bad control method
• Rarely more than 80% accurate
 Different standards for each inspector

13. Inspection Types and Limitation
Source Inspection Informative Inspection Judgment Inspection
• As close to the source
of the defect as
possible
• Mistakes can be
reworked or corrected.
• Investigates the cause
of any defect found so
action can be taken
• Inspector attempts to
separate good units
from bad units after
processing has
occurred
Limitation:
It requires 100 percent of
a work force to inspect its
work all the time
Limitation:
It only provides
information after the
defect has occurred
Limitation:
It does not decrease the
defect rate.

14. 6. SOP (Standard Operating Procedure)
Attempts to prevent the error through
properly executing task documented in on
SOP
E.g.: Manufacturing SOP’s and audits

15. 7. Warning Signal
Attempts to detect defect
If signals occur often , operator
become immune or simply disconnect
these warning signal
e.g.: Blinking or flashing light
Buzzers
Spell checker notification

16. Types of Human Errors and safeguards
Human Errors
Forgetfulness
Errors due to misunderstanding
Errors in identification
Errors made by amateurs
Willful errors
Inadvertent errors
Errors due to slowness
Errors due to lack of standards or
supervision
Surprise errors
Intentional errors
Safeguards
Altering operator in advance, checking at
regular intervals
Training, standardization
Training, attentiveness, vigilance ,
Skill building, standardization
Basic education, Experience
Attentiveness, discipline, standardization
Skill Building, Standardization
Work instruction, standardization
Total productive maintenance
Discipline, fundamental education