Error Proofing

Techniques

Slide 1
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES

AGENDA
 OPENING COMMENTS & INTRODUCTIONS
 ERROR PROOFING OVERVIEW
 WORKSHOP EXPECTATIONS - Why Are We Here
Problem Statement
 DEFINE CURRENT STATE
 ERROR PROOFING AWARENESS & TECHNIQUES
 BRAINSTORMING - Problem Solving Solutions Utilizing
Error Proofing Techniques
 DEVELOP ACTION PLANS & IMPLEMENTATION
 CLOSING & WRAP-UP

Slide 2
Error Proofing Techniques
 QUALITY STEP CHART

ABC Company - Widget Assemblies

INCIDENTS PER
PART OR PPM
Current
SAMPLE CHART ACTION PLANS WITH
State ACTUAL OR EST. RESULTS
Improved
Processing = 140 ppm

Reduced
Handling = 120 ppm
QUALITY MEASURE
Visual
Management = 100 ppm

Error
Proofing = 80 ppm

Preventative
Maintenance = 60 ppm

TARGET

TIME
TIME FRAME OF
ACTION PLANS
© Copyright General Motors. All rights reserved.

Slide 3
Error Proofing Techniques
 MAKE ALL PEOPLE DEFINE
AFFECTED AWARE CURRENT
PROJECT OF WHAT IS SITUATION
SELECTION GOING TO HAPPEN
• CUSTOMER QUALITY CONCERN
SELECT • PROCESS FLOW & DATA WORKSHEETS
• HIGH RPPM / REPEAT PR/R’s
• PART IN CONTROLLED SHIPPING
• CHRONIC QUALITY PROBLEM
TEAM MEMBERS •
•
QUALITY RESULTS
PROCESS MEASURES
• GM PRODUCT/PROCESS ENGINEER • PROBLEM DEFINITION
• HIGH WARRANTY IMPACT
• SUPPLIER PERSONNEL (ENGR., MFG,
• HIGH COST OF QUALITY
QUALITY, OPERATORS, ETC)
• PURCHASING
• SUPPLIER QUALITY ENGINEER
• CUSTOMER REPRESENTATIVE

IDENTIFY
LOOK FOR NEW
POSSIBLE
OPPORTUNITIES
CAUSES

Process
• BRAINSTORMING
• 5 WHY’s
• CAUSE & EFFECT DIAGRAM
• STORYBOARD
• COLLECT THE DATA
• RUN CHARTS
• FREQUENCY DISTRIBUTION
• PICTOGRAPH
RECOGNIZE • SCATTER DIAGRAMS
• PROCESS CAPABILITY STUDY

EFFORTS OF • DESIGN OF EXPERIMENTS

• PROCESS DISSECTION

PEOPLE

EVALUATE
AND ADJUST
OPERATION:
FROM:___________________________ QUANTITY PER SHIFT:______________ CUSTOMER CYCLE TIME:__________________

TO: _____________________________ SHIFT:________ OPERATOR CYCLE TIME:__________________

DESCRIPTION OF ELEMENT TIME STANDARD IN- QUALITY CRITICAL
NO. OPERATION HAND WORK
MACHINE
WALK PROCESS STOCK Q CHECK C OPERATION SAFETY

1 5
ANALYZE THE DATA
2

3
4
PLAN & IMPLEMENT SELECT GOOD IDEAS
WORKSTATION AREA DRAWN TO SCALE

03/23/94
CORRECTIVE ACTION • GATHER NEW DATA AS NECESSARY.
• DEVELOP ACTION PLANS FOR CONTAINMENT,
CORRECTION, AND PREVENTION.
• EVALUATE EFFECTIVENESS OF THE • BASED ON PROFOUND KNOWLEDGE • DOCUMENT RECOMMENDED CHANGES AND
ACTION PLANS. • OVERCOMING ROADBLOCKS ACTION PLANS.
• MEDIAN & RANGE CHARTS • ACTION PLANS PROCESSED ASAP • ESTABLISH IMPLEMENTATION TIMING AND
• AVERAGE & RANGE CHARTS
RESPONSIBILITY.
• PROCESS CAPABILITY
WHAT IS AN ERROR???
• Errors are inadvertent, unintentional,
accidental mistakes made by people
because of the human sensitivity
designed into our products and
processes

• Errors result in those “once in a while”

defects that we always find difficult to
control

Slide 5
Error Proofing Techniques
Inadvertent errors are
not only possible but
inevitable.

Slide 6
Error Proofing Techniques
EXAMPLES OF ERRORS AT HOME . . .

• Running out of gas

• Locking keys in your car

• Forgetting to stop

• Forgetting to turn off the coffee

pot

• Forgetting to unplug the iron

Slide 7
Error Proofing Techniques
What if you had to write your name 1500 times
every day?

With all of life’s distractions......

Are you 100% sure that you would never make a

mistake?!!!!

Slide 8
Error Proofing Techniques
EXAMPLES OF ERRORS AT WORK . . .
• Missing Parts
° Forgetting to assemble a part - screws, labels, orifice tubes...

• Misassembled Parts
° Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...

• Incorrect Processing
° Disposing of a part rejected at test to the wrong pile

• Incorrect Parts
° Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...

Slide 9
Error Proofing Techniques
WHAT ABOUT ERRORS AT WORK?

INJURIES

Mistakes = Lost Time, Lost

Money, and
possibly Lost
Business!!!!

Slide 10
Error Proofing Techniques
PROBLEM SELECTION CRITERIA

• High Parts per Million

• High PR/R Frequency
• Chronic Quality Problem
• High Cost of Quality
• PFMEA Identified Areas
• High Warranty Cost

Slide 11
Error Proofing Techniques
PROBLEM STATEMENT

LOST

Slide 12
Error Proofing Techniques
EFFECTS OF PROBLEM

CUSTOMER SUPPLIER

Slide 13
Error Proofing Techniques
 WHY DO HUMAN
ERRORS OCCUR
WHEN EVERYONE
IS FOR QUALITY?

Slide 14
Error Proofing Techniques
WHY DO ERRORS HAPPEN?

The quality of an operator dependent process is affected by the:


Knowledge (Skill)
Operator
Vigilance (Attention to detail)

An operator must have knowledge of the job in order to know

what to do and when a quality part has been produced
In addition, a knowledgeable operator may have to be vigilant
with each part produced to be sure it meets all the quality
expectations

Slide 15
Error Proofing Techniques
KNOWLEDGE AND VIGILANCE

EXAMPLE:
I may be an expert at driving
a car (KNOWLEDGE)

BUT.....

Occasionally, I lock my keys

in the car or run out of gas
(LACK OF VIGILANCE!!!)

Slide 16
Error Proofing Techniques
 People
People Variation
Variation

Relief Breaks

Rotation
Overtime
Coverage Various People Doing Only One Job!!!!

Shift-Shift
Transfers Various:
 Levels of Training
Farm-Ins  Knowledge of Total Product
 Knowledge of Customer Requirements
 Methods of Performing Job

Slide 17
Error Proofing Techniques
 People
People Variation
Variation

Relief Breaks

KNOWLEDGE
Rotation
Overtime
Coverage Various People Doing Only One Job!!!!

Shift-Shift
Transfers Various:
 Levels of Training
Farm-Ins  Knowledge of Total Product
 Knowledge of Customer Requirements
 Methods of Performing Job

Slide 18
Error Proofing Techniques
 People
People Distractions
Distractions

What do you think of this new design?

Overtime tonight?

This is how this job goes... Boredom

There’s a problem with the parts you’re making.... Break time!!!

Machine’s down...
What are you doing tonight?

OOPS!!!!!!

Slide 19
Error Proofing Techniques
 People
People Distractions
Distractions

What do you think of this new design?

Overtime tonight?

VIGILANCE
This is how this job goes... Boredom

There’s a problem with the parts you’re making.... Break time!!!

Machine’s down...
What are you doing tonight?

OOPS!!!!!!

Slide 20
Error Proofing Techniques
 WHY ARE MISTAKES A
PROBLEM?
Cost us money

Cost us time

Cause us danger/possible injury

Slide 21
Error Proofing Techniques
THINGS DONE RIGHT 99.9% OF
THE TIME MEANS . . .
• One hour of unsafe drinking water per month
• Two unsafe landings at O’Hare Airport each day
• 16,000 lost pieces of mail per hour
• 20,000 incorrect drug prescriptions per year
• 500 incorrect surgical operations per week
• 50 newborn babies dropped each day by doctors
• 22,000 checks per hour deducted from wrong accounts
• 32,000 missed heartbeats per person each year

Slide 22
Error Proofing Techniques
 THE ERROR PROOFING
ATTITUDE
• People CAN and WILL make inadvertent
mistakes!
• If one person makes a mistake - ANYONE
can!
• ONE mistake out the door is too many!!
• Mistakes CAN be eliminated and MUST be
eliminated for us to become
COMPETITIVE!!!!

Slide 23
Error Proofing Techniques
 WHAT DO WE DO?

If errors are so easy to make, how will we ever

send our customers 100% good product?????

By designing our products and processes

so that they minimize the opportunity
for the mistake to happen in the first place

This
Thisisiswhere
wherethe
theconcept
conceptof
of
ERROR
ERRORPROOFING
PROOFING
comes
comesin.......
in.......

Slide 24
Error Proofing Techniques
 A SYSTEM IS NEEDED
TO COMBAT THESE DRAWBACKS:

• Detect an error in the process before a defective

product is passed to the next station; whenever
possible before a defective product is produced.

• Perform detection and notification of operator

immediately; i.e. for every unit of product.

Slide 25
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES

BENEFITS
Assures 1st Piece Quality
Assures Consistency during Set-Ups
Prevents Production of Defective Parts
Makes Quality Problems More Visible
Creates a Safer Work Environment
Eliminates Waste of Inspection and Repair
Lowers Cost of Design (DFM) and Cost to
Manufacture (Poka-Yoke Devices)

Slide 26
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES

OBJECTIVE

To improve the PROCESS by helping

people prevent ERRORS and increase the
chances of DETECTION, so that FAILURE
MODE occurrences are
ELIMINATED.

Slide 27
Error Proofing Techniques
 Error Proofing Techniques

• INTRODUCTIONS / OPENING COMMENTS.

• OVERVIEW OF SITE OPERATIONS AND DISCUSSION OF

PROBLEM AREA(S).

• WORKSITE REVIEW TO ASSESS PROBLEM AREA FOCUS

AND ISSUES.

• OVERVIEW OF WORKSHOP PROCESS AND ACTIVITIES.

• PRE-WORKSHOP PREPARATION REQUIREMENTS.

• GENERAL DISCUSSION AND ADJOURN.

Slide 28
Error Proofing Techniques
Error Proofing
Techniques

Slide 29
Error Proofing Techniques
 QUALITY STEP CHART

ABC Company - Widget Assemblies

INCIDENTS PER
PART OR PPM
Current
SAMPLE CHART ACTION PLANS WITH
State ACTUAL OR EST. RESULTS
Improved
Processing = 140 ppm

Reduced
Handling = 120 ppm
QUALITY MEASURE
Visual
Management = 100 ppm

Error
Proofing = 80 ppm

Preventative
Maintenance = 60 ppm

TARGET

TIME
TIME FRAME OF
ACTION PLANS
© Copyright General Motors. All rights reserved.

Slide 30
Error Proofing Techniques
 MAKE ALL PEOPLE DEFINE
AFFECTED AWARE CURRENT
PROJECT OF WHAT IS SITUATION
SELECTION GOING TO HAPPEN
• CUSTOMER QUALITY CONCERN
SELECT • PROCESS FLOW & DATA WORKSHEETS
•
•
•
HIGH RPPM / REPEAT PR/R’s
PART IN CONTROLLED SHIPPING
CHRONIC QUALITY PROBLEM
TEAM MEMBERS •
•
QUALITY RESULTS
PROCESS MEASURES
• GM PRODUCT/PROCESS ENGINEER • PROBLEM DEFINITION
• HIGH WARRANTY IMPACT • SUPPLIER PERSONNEL (ENGR., MFG,
• HIGH COST OF QUALITY
QUALITY, OPERATORS, ETC)
• PURCHASING
• SUPPLIER QUALITY ENGINEER
• CUSTOMER REPRESENTATIVE

IDENTIFY
LOOK FOR NEW
POSSIBLE
OPPORTUNITIES
CAUSES
• BRAINSTORMING

Process •
•
•
5 WHY’s
CAUSE & EFFECT DIAGRAM
STORYBOARD
• COLLECT THE DATA
• RUN CHARTS
• FREQUENCY DISTRIBUTION
• PICTOGRAPH
RECOGNIZE • SCATTER DIAGRAMS
• PROCESS CAPABILITY STUDY

EFFORTS OF • DESIGN OF EXPERIMENTS

• PROCESS DISSECTION

PEOPLE

EVALUATE
AND ADJUST
OPERATION:
FROM:___________________________ QUANTITY PER SHIFT:______________ CUSTOMER CYCLE TIME:__________________
TO: _____________________________ SHIFT:________ OPERATOR CYCLE TIME:__________________
DESCRIPTION OF ELEMENT TIME STANDARD IN- QUALITY CRITICAL
NO. OPERATION HAND WORK
MACHINE
WALK PROCESS STOCK Q CHECK C OPERATION
SAFETY

1 5
ANALYZE THE DATA
2

3
4
PLAN & IMPLEMENT SELECT GOOD IDEAS
WORKSTATION AREA DRAWN TO SCALE
03/23/94
CORRECTIVE ACTION • GATHER NEW DATA AS NECESSARY.
• DEVELOP ACTION PLANS FOR CONTAINMENT,
CORRECTION, AND PREVENTION.
• EVALUATE EFFECTIVENESS OF THE • BASED ON PROFOUND KNOWLEDGE • DOCUMENT RECOMMENDED CHANGES AND
ACTION PLANS. • OVERCOMING ROADBLOCKS ACTION PLANS.
• MEDIAN & RANGE CHARTS • ACTION PLANS PROCESSED ASAP • ESTABLISH IMPLEMENTATION TIMING AND
• AVERAGE & RANGE CHARTS
RESPONSIBILITY.
• PROCESS CAPABILITY
 Error Proofing Techniques
Agenda

 OPENING COMMENTS & INTRODUCTIONS

 ERROR PROOFING OVERVIEW
 WORKSHOP EXPECTATIONS - Why Are We Here Problem
Statement
 DEFINE CURRENT STATE
 ERROR PROOFING AWARENESS & TECHNIQUES
 BRAINSTORMING - Problem Solving Solutions Utilizing Error
Proofing Techniques
 DEVELOP ACTION PLANS & IMPLEMENTATION
 CLOSING & WRAP-UP

Slide 32
Error Proofing Techniques
PROBLEM SELECTION CRITERIA

• High Parts per Million

• High PR/R Frequency
• Chronic Quality Problem
• High Cost of Quality
• PFMEA Identified Areas
• High Warranty Cost

Slide 33
Error Proofing Techniques
PROBLEM STATEMENT

LOST

Slide 34
Error Proofing Techniques
EFFECTS OF PROBLEM

CUSTOMER SUPPLIER

Slide 35
Error Proofing Techniques
 WHY ARE MISTAKES A PROBLEM?

 Cost us money

 Cost us time

 Cause us danger/possible injury

Slide 36
Error Proofing Techniques
THINGS DONE RIGHT 99.9% OF
THE TIME MEANS . . .
• One hour of unsafe drinking water per month
• Two unsafe landings at O’Hare Airport each day
• 16,000 lost pieces of mail per hour
• 20,000 incorrect drug prescriptions per year
• 500 incorrect surgical operations per week
• 50 newborn babies dropped each day by doctors
• 22,000 checks per hour deducted from wrong accounts
• 32,000 missed heartbeats per person each year

Slide 37
Error Proofing Techniques
 THE ERROR PROOFING ATTITUDE
 People CAN and WILL make inadvertent mistakes!
 If one person makes a mistake - ANYONE can!
 ONE mistake out the door is too many!!
 Mistakes CAN be eliminated and MUST be eliminated for us to
become COMPETITIVE!!!!

Slide 38
Error Proofing Techniques
 A SYSTEM IS NEEDED
TO COMBAT THESE DRAWBACKS:

• Detect an error in the process before a defective

product is passed to the next station; whenever
possible before a defective product is produced.

• Perform detection and notification of operator

immediately; i.e. for every unit of product.

Slide 39
Error Proofing Techniques
 WHAT IS ERROR PROOFING?

Error
ErrorProofing
Proofingis
isthe
theactivity
activityof
ofawareness,
awareness,detection,
detection,and
and
prevention
preventionof
oferrors
errorswhich
whichadversely
adverselyaffect:
affect:
Our
Ourcustomers
customers (defects)
(defects)
Our
Ourpeople
people (injuries)
(injuries)
and
andresult
resultin
inWASTE!
WASTE!

Awareness: Having the forethought that a mistake can be made, communicating the potential, and
planning the design of the product or process to detect or prevent it.

Detection: Allowing the mistake to happen but providing some means of detecting it and alerting
someone so that we fix it before sending it to our customer.

Prevention: Not allowing the possibility for the mistake to occur in the first place.

Slide 40
Error Proofing Techniques
 ERROR PROOFING
Techniques
• Design for Manufacturability
• “Poka-Yoke” System Devices

Slide 41
Error Proofing Techniques
 ERROR PROOFING
Techniques:
• Design For Manufacturability (DFM)

Technique that Results in Designs that Cannot be

Incorrectly Manufactured or Assembled. This
Technique can also be used to “Simplify” the
Design and therefore reduce its cost.

Slide 42
Error Proofing Techniques
 ERROR PROOFING

Techniques (Continued)
• “Poka-Yoke” System*

Set-Up Devices or Inspection Techniques that Assure

that Set-Up is Done Correctly; i.e. Produces 100%
Good Parts from the First Piece on

“Zero Quality Control: Source Inspection and the Poka-Yoke System” - Shigeo Shingo; 1986

Slide 43
Error Proofing Techniques
 EXAMPLES OF ERRORS AT WORK . . .

 Missing Parts
 Forgetting to assemble a part - screws, labels, orifice tubes...

 Misassembled Parts
 Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...

 Incorrect Processing
 Disposing of a part rejected at test to the wrong pile

 Incorrect Parts
 Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...

Slide 44
Error Proofing Techniques
 Identify Error Proofing Opportunities
• PFMEA
IDENTIFY • Quality Data, PR/R, Warranty Data...
• Brainstorm (Questions to Ask, Free Form...)

Prioritize Opportunities (RPN, Pareto...)

Determine Level of Error Proofing

HOW
HOW
ANALYZE Brainstorm Error Proofing Mechanisms
• Build on past experience
• Can use more than one mechanism
TO
TO Select Error Proofing Mechanism
• Most cost effective
• Simple
ERROR
ERROR Plan (Process Mechanisms)
PLAN • Action plan
• Error Proofing Control Plan (EPCP)
PROOF
PROOF Implement Error Proofing Mechanism
•Installation
IMPLEMENT •Validation
• EPCP
•Check sheet/Log
•Operator Instructions

EVALUATE Evaluate Results

Slide 45
Error Proofing Techniques
 TOOLS FOR ANALYSIS

Flow Chart Fishbone Diagram Pareto Chart

Problem

Histogram 5 Why’s Run Chart

Problem
Why
Why
Why
Why
Why
Root Cause

Scatter Plot Control Chart Pictograph

Slide 46
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES

BENEFITS

Assures 1st Piece Quality

Assures Consistency during Set-Ups
Prevents Production of Defective Parts
Makes Quality Problems More Visible
Creates a Safer Work Environment
Eliminates Waste of Inspection and Repair
Lowers Cost of Design (DFM) and Cost to
Manufacture (Poka-Yoke Devices)

Slide 47
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

SENSOR INFORMATION:
BASIC TYPES OF SENSORS
• Discrete sensors
• Analog sensors

TYPES OF PRESENCE SENSORS

• Physical contact
• No physical contact

TYPES OF NON-CONTACT SENSORS

• Reed relays
• Inductive
• Capacitive
• Photoelectric sensors

ADVANTAGES OF THE VARIOUS TYPES

• Functionality
• Costs
• Areas of application

Slide 48
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

BASIC TYPES OF SENSORS:

ANALOG SENSORS
• Answer the question: “Where is the part?”
or
• “To what level have we filled the container?”

DISCRETE SENSORS
• The part is present or is not present.
• Most frequently asked question in a manufacturing
operation.

Slide 49
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF PRESENCE SENSORS:

PHYSICAL CONTACT
• e.g. Limit switches
• Advantages - Can carry more current
- Gap between terminals

NO PHYSICAL CONTACT
• Advantages - No physical contact
- Better for counting sensitive surfaces,
e.g. painted or polished surfaces
- No moving parts
- Faster

Slide 50
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

REED RELAYS
• Target is magnetic
• Will not respond to non-magnetic targets
with reliability.

INDUCTIVE
• Based on metal targets; will not respond
to non-metallic targets with high reliability.

CAPACITIVE
• Cannot distinguish between the real target
and something else in the target region.
Must control what comes close to the target.

PHOTOELECTRIC
• Can be fooled by a non-target.
Slide 51
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

REED RELAYS
Typical range: Up to 1.5 in. (approx. 4 cm)
• Two hermetically sealed metal foil reeds which make contact
with each other to close the circuit, when in the vicinity of a
magnet (permanent or electro-magnet).
• The differential is determined by differencing the point of first
contact from the point of last contact.
• Magnet approach must be in a direction parallel to the direction
of the line connecting the tow reeds.

Best applications for magnetically actuated switches in general:

• Security and safety
• to avoid false tripping
• security door interlock for heavy machinery; end of travel
for elevators, cranes, and the like.
• Sensing through walls (non-ferrous, e.g. Aluminum and
Magnesium).
• Pallet identification in synchronous automated assembly lines.
• Relative dirty environments (e.g. dust, dirt, sand, oil, or coolant
fluids).
• Whenever high response speeds are required.

Disadvantages - poor long-term reliability (moving parts)

Slide 52
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

INDUCTIVE SENSORS
• Principle of Operation:
• Eddy currents are induced in the target (metallic)
by the electromagnetic.
• The target reacts with the Eddy currents as a
function of the distance from the field.
• Inside the field, the target attenuates the magnitude
of the Eddy currents.
• Outside the field, the target does not impede the
Eddy currents.
• This type of oscillator is referred to as a ECKO
(Eddy Current Killed Oscillator).

Slide 53
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
TYPES OF NON-CONTACT SENSORS:
CAPACITIVE SENSORS
• Principle of Operation:
• Senses all materials
• Contain a high frequency oscillator with one of its
capacitor plates built into the sensor.

• Method of Application:
• All materials are sensed through a change on the
dielectric characteristics.
• Ideal applications include bulk materials and liquids
in containers of glass and plastic.

• Characteristics:
• Poor choice for metal targets.
• Is very sensitive to environmental factors.
• Sensing range depends greatly on the material being
sensed.
• Can be misled and therefore it is important to control
the material which is presented to the sensor.
Slide 54
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

PHOTOELECTRIC SENSORS
Photoelectric controls need no physical contact and are ideal where sensed
objects must remain untouched. Photoelectric controls respond rapidly to
parts moving quickly and in varying positions along a conveyor, yet operate
dependably if actuated only infrequently. There are controls for indoor or
outdoor use, for varying ambient light conditions, for high vibration, for areas
restrictive in space, and even for explosive locations.

Typical applications include:

• Counting • Edge guide
• Labeling • Web break detection
• Conveyor control • Regristration control
• Bin level control • Food processing
• Parts inspection • Parts monitoring and sorting
• Feed and/or fill control • Batch counting
• Package handling • Robotics
• Thread break detection • Parts handling

Slide 55
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

PHOTOELECTRIC SENSORS
Conveyor Control
This application involves sorting brown cardboard boxes which are coded with up to four black marks per
box. The application is to sense the number of marks on each box.
Package Handling
A diffuse scan photoelectric control is used to detect the light reflected from the object in this application.
The control detects the light reflected off the box, turning ON and OFF the gluing machine.
Labeling
This application is designed to detect the leading edge of a black bar code on a read and write label. The
labels are edge to edge on a spool. When the bar code is detected the sensor output triggers a laser bar
code reader which reads the bar code.
Food Processing
This application monitors the level of an accumulator in a meat processing facility. A photoelectric control
detects a fill level of hot-dogs in the accumulator then turns on the conveyor for a preset time period. Side
walls of the accumulator are polished stainless steel. The equipment is subject to daily washdown.
Fill Level Control
This application inspects the fill level of various jars of food products. The photoelectric system produces
an output when either an under or over fill condition is detected.
Parts Handling
Fiber optics are ideal for areas too small for a standard photoelectric control. The fiber optic cables direct
the light from the base to where the sensing is needed.

Slide 56
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors
THRU

Emitter Receiver

Target
Thru: Advantages:
• Light source (emitter) and 1. Most reliable when target is opaque
receiver are placed opposite 2. Long range scanning, most excess gain
each other. 3. Use in high contamination areas, dirt, mist,
• The object to be detected condensation, oil film, etc.
passes between the two. 4. Precise positioning or edge-guiding of opaque
material
5. Parts counting
Slide 57
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors

Target

Diffuse: Advantages:
• Light beam is directed at the 1. No reflector required.
object to be detected. 2. Convenient for installation.
• Light will be reflected off the 3. One sided scanning.
object in many directions.
4. Senses clear materials when
• Some of the light reflected from distance is not fixed.
the object will be sensed by the
5. Ease of alignment
receiver.
Slide 58
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

PHOTOELECTRIC SENSORS

Proximity (diffuse) Background Suppression

Background suppression utilizes 2 receivers behind the receiving lens. They are
aimed at a precise point in front of the unit and sense the presence of a target
when the output of both receives are equal.

Applications:

• Material handling - conveying systems

• Collision detection for AGV’s (Automatic Guided Vehicles)
• Car / truck wash
• Level sensing

Slide 59
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors

Reflector

Retroreflective

Target

Retroreflective: Advantages:
• Light beam is directed at a reflective target 1. One-sided scanning
(reflector, tape or other reflective object) - 2. Ease of alignment
one which returns light along the same
3. Immune to vibration
path it was sent.
• The object to be detected passes between
photoelectric control and reflective target.
Slide 60
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors
Convergent Beam

Fixed
Distance Target

Convergent: Advantages:
• Light beam is directed at object to be 1. First choice for detecting clear
detected (ignores background materials
surfaces) 2. Ignores unwanted background
• Object must be at a given distance in surface reflection
relationship to photoelectric control 3. Detects objects with low reflectivity
before light will be reflected to receiver
4. Detects height differential
Slide 61
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

TYPES OF NON-CONTACT SENSORS:

PHOTOELECTRIC SENSORS
Fiber Optic Sensors
What do you do when the physical constraints of the application don’t allow for
installing regular, self-contained sensors? Maybe the target is in a high temperature
or chemically aggressive environment. Perhaps the target is small or very fast-moving.
Fiber-optics, applied to photoelectric scanning, solves these problems.
Fiber Optics and Sensing
All fiber optic sensing mode are implemented using one type of amplifier which contains
both emitter and receiver in one housing.
Fiber Optic Thru-beam Scanning
Using two opposed, individual fiber optic cables, the object to be detected breaks the
beam. The target must be at least the same dimension as the effective beam, which in
this case, is the bundle diameter. Because the beam is very small, the detection can be
very precise. A typical application might be edge detection for a web printing press.
Needle tips reduce the beam dimension for use with extremely small targets, typical for
application in semiconductors and pharmaceutical industries.
Typical application:
• Small parts detection
• Edge detection
• High temperature environment (600 degrees F+)
Slide 62
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors
Thru

Target or
Reflector

Fiber Optic:
• Not a scanning technique but rather another way of transmitting light beam.

Advantages:
1. High temperature applications 4. Corrosive areas
2. Where space is limited 5. Noise immunity
3. Size and flexibility of fiber leads 6. Color sensing
Slide 63
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors

Photoelectric Sensors

Special
Reflector
Polarized

Target

Polarized: Advantages:
• Will work only with comercube 1. One-sided sensing
reflector or special polarized 2. Does not false trigger off
reflective tape. highly reflective object
• Will not false trigger when 3. Senses clear materials
sensing shiny object. 4. Ease of alignment
5. Immune to vibration
Slide 64
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
APPLICATIONS FOR PHOTOELECTRIC SENSORS
APPLICATION SCAN TECHNIQUE
Small parts detection Fiber optics or Thru scan with aperatures
Long distance scanning Thru scan
High temperature sensing Fiber optic
Shiny object or film detection Polarized scan
Severe environment (Extreme dust or dirt) Thru scan
Limited mounting space Fiber optic
Explosive environment Thru scan or Retro
Washdown environment Thru, Retro-reflective or Diffuse
Analog position sensing Diffuse or Fiber Optic
Conveyor Monitor Polarized, Diffuse or Retro
- Jam detection
- Part count
- Part position
Vibratory Feeder Fiber optic
Lid or Cap detection Convergent beam or Fiber Optic
Clear bottle detection Polarized or Fiber Optic
Transparent material Polarized scan
Label detection Diffuse or Fiber Optic
Bin or hopper level Thru when using window Diffuse from above
Mold or die clear to close Thru scan or Fiber Optic (high temp)
Max height monitor (i.e. Fork trucks) Thru scan
Opaque material on semitransparent carrier Thru scan
Motion detection All scan type
Slide 65
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
ADVANTAGES DISADVANTAGES APPLICATIONS
Magnet Operated - Inexpensive - Magnet required - Security and safety
(reed relay) - Very selective target - Sensitive to welding interlocking
identification fields - Sensing thru metal

Hall Effect - Complete switching - Magnetic target only - Keyboard

function is in a single - Extremely sensitive to
integrated circuit industrial environment
- Operates up to 150khz
- High temperature
(150 degrees C)
- Good resolution

Ultrasonic - Senses all materials - Resolution - Anti-collision on AGV

- Repeatability Doors
- Sensitive to background
and environment changes
- Distance limitation to
60mm

Inductive - Resistant to harsh - Presence detection on all

environments kinds of machines
- Easy to install - Very popular
- Very predictable

Capacitive - Senses all materials - Very sensitive to - Level sensing with liquids
- Detects through walls environment changes and non-metallic parts

Photoelectric - Senses all materials - Subject to contamination - Parts detection

- Material handling
- Packaging
- Very popular

Piezo-electric - Torque (automated or

manual)
Slide 66
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

NEW APPLICATIONS:
• Pressure sensing
• Shape sensing
• Weight sensing
• Presence sensing
• Color sensing (dark vs light)
• Torque sensing (Piezo-electric)
• Position sensing
• Custom / adaptive size parts
• Vacuum sensing
• Flow sensing (e.g. gallon / minute)

Slide 67
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

POKA-YOKE Sensors at a Deming Prize Winner

1. Mechanical 9. Heat Sensor

2. Magnetic 10. Gas Sensor

3. Beam Cut 11. Force Sensor

4. Super Sonic 12. Torque Sensor

5. Image Sensor 13. Meter Relay

6. Counter 14. Vibration Sensor

7. Beam Reflector 15. Automatic Measurement

8. Pressure Sensor

Slide 68
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

THE MOST EFFECTIVE TYPES OF ERROR NOTIFICATION MEANS

Getting the Operator’s Attention:

• Visual Signal (flashing light is best)
• Audio Signal (loud and persistent, e.g. burglar alarm)
• Protective Barrier (to prevent defect or operator injury)
• When used: low defect occurrence rate and when
repairs can be made.

Shutting Down the Operation:

• Upon detecting a “non-conformance” the operation
is simply shut down, i.e. the next part will not be
processed.
• When used: relatively higher occurrence rates and
when repairs are not possible.

Slide 69
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

EXAMPLES OF POKA-YOKE’S
FOR THE THREE MOST COMMON PROBLEMS
Error Proofing Type of Type of
Problem Type
Installed Sensor Used Intervention Used
Missing Components Counter to verify Micro-switch Machine interlock
correct number of
components

Pre-counting the None None

number of components

Fixture at the operation Proximity switch Machine interlock

to detect the presence
of component from the
previous operation

Incorrect Processing Process sequence None (all fixtures None

fixturing specially designed)

Wrong Components Verifying component Light transmission Video or audio alarms

shape, weight, or
dimension switches

Slide 70
Error Proofing Techniques
 ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT

BEST SENSING IDEAS

What is the best method for sensing fluid levels
for a machine?
What is the best method for sensing magnets for
electric motors?
What are three possible methods for sensing burs
on a cylinder bore?

What is the best method for detecting the presence

of an O-ring?

Slide 71
Error Proofing Techniques
 Four Categories of Errors - Questions to Ask????

Missing Parts
° Is there a model mix such that some models
require a part while others require nothing at all in
that location?

° Is the part assembled as a small part after some

main activity?

° Is the part difficult to see after being assembled?

Slide 72
Error Proofing Techniques
 Missing
Missing Parts
Parts
Is the part :
Is the part :
Unseen or untouched in
Unseen or untouched in
subsequent process steps? Implement operator instructions,
subsequent process steps? NO
Difficult to see during assembly? visual aids and training as minimum
Difficult to see during assembly?
Difficult to assemble? requirement
Difficult to assemble?
Difficult to see after assembly?
Difficult to see after assembly?
Difficult to differentiate between pre
Difficult to differentiate between pre
and post assembly?
and post assembly?
YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process? YES
in design of product/process?
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?
NO
What can be done to detect whether
What can be done to detect whether Implement Error Proofing
the part has been assembled?
the part has been assembled? (process/design change and/or
Detection device - torque detect/lock out device)
Detection device - torque
counter, photoelectric eye over
counter, photoelectric eye over
container, limit switch at Verify results
container, limit switch at
dispenser,....
dispenser,....

Lock out subsequent operation if part

Lock out subsequent operation if part
is missing.
is missing.
Lock out device - limit switch,
Lock out device - limit switch,
conductivity sensor...
conductivity sensor...

Slide 73
Error Proofing Techniques
 Brainstorm Error Proofing Mechanism

Missing Parts - Thought Starters

• Make visible/obvious if missing
° Color contrast
° Visible at numerous operations and pack
° Use mirrors
° Position of part as moves down line
° Visual aid/picture posted with part present and highlighted
• Redefine process
° Assemble early in process
° Successive check
° Rearrange multiple write-up to eliminate “sometimes do/sometimes don’t”
• Monitor part supply
° Only supply parts needed for that model (no questions-if there are parts present, use them)
° Lot control, count parts-must equal # pieces produced
• Sensors
° Photoelectric eyes to detect, lock out until corrected
° Limit switch to detect, lock out until corrected
• Modify design
° Eliminate part

Slide 74
Error Proofing Techniques
Four Categories of Errors-Questions to Ask????

 Misassembled Parts
° Is the operation difficult for the operator to see as
they perform the job?

° Is there an assembly or positioning operation that

can be completed incorrectly?

Slide 75
Error Proofing Techniques
 Misassembled
Misassembled Parts
Parts
Is the part :
Is the part :
Difficult to see during assembly?
Difficult to see during assembly?
Difficult to assemble? Implement operator instructions,
Difficult to assemble?
Difficult to see after assembly? NO visual aids and training as minimum
Difficult to see after assembly?
Difficult to differentiate between pre requirement
Difficult to differentiate between pre
and post assembly?
and post assembly?
Lacking guides or fixtures for proper
Lacking guides or fixtures for proper
assembly or proper alignment?
assembly or proper alignment?
YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process?
in design of product/process?
(guides, fixtures, automation)
(guides, fixtures, automation) YES
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?

NO
Implement Error Proofing
What can be done to detect whether
What can be done to detect whether (process/design change and/or
the part has been misassembled?
the part has been misassembled? detect/lock out device)
Detection device - torque counter,
Detection device - torque counter,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch

Lock out subsequent operation if part

Lock out subsequent operation if part
is misassembled.
is misassembled.
Lock out device - limit switch,
Lock out device - limit switch,
conductivity sensor...
conductivity sensor...

Slide 76
Error Proofing Techniques
Brainstorm Error Proofing Mechanism

Misassembled Parts- Thought Starters

• Visual aids
° Visual aid/picture posted with correct position highlighted
• Redefine process
° Assemble early in process
° Successive check
• Workplace organization
° Organize for maximum ease and visibility
• Sensors
° Photoelectric eyes to detect, lock out until corrected
° Limit switch to detect, lock out until corrected
• Modify/design fixture
° Unable to assemble incorrectly
• Modify design
° Eliminate part
° Prevent misassembly - e.g. two sizes of studs
° Provide guides or references

Slide 77
Error Proofing Techniques
Four Categories of Errors-Questions to Ask????
 Incorrect Processing
 Is there an operation that requires a recognition of some
characteristic to determine what to do with the part next?

GOOD REJECTS

Slide 78
Error Proofing Techniques
 Incorrect
Incorrect Processing
Processing
Does the operation require recognition
Does the operation require recognition
of some characteristic to determine
of some characteristic to determine
what to do with the part? Implement operator instructions,
what to do with the part?
NO visual aids and training as minimum
(e.g. Red light indicates place in reject requirement
(e.g. Red light indicates place in reject
pile, visual inspection for pre-defined
pile, visual inspection for pre-defined
defects)
defects)

YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process?
in design of product/process?
(fixtures, automation)
(fixtures, automation) YES
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?

NO
What can be done to detect whether
What can be done to detect whether Implement Error Proofing
the part has been incorrectly
the part has been incorrectly (process/design change and/or
processed?
processed? detect/lock out device)
Detection device - reset button,
Detection device - reset button,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch

Lock out subsequent operation if part

Lock out subsequent operation if part
is incorrectly processed.
is incorrectly processed.
Lock out device - limit switch,
Lock out device - limit switch,
conductivity sensor...
conductivity sensor...

Slide 79
Error Proofing Techniques
 Brainstorm Error Proofing Mechanism

Incorrect Processing- Thought Starters

• Visual aids
° Quality alert indicating high potential for error
° Fixture or template outlining pre-defined defects
° Bogey or sample boards for visual inspection
• Redefine process
° Reset or acknowledge but at the appropriate next
operation
° Automate
• Workplace organization
° Separate and clearly label reject locations/containers
• Sensors
° Photoelectric eyes to detect, lock out until corrected
° Limit switch to detect, lock out until corrected

Slide 80
Error Proofing Techniques
Four Categories of Errors-Questions to Ask????

 Incorrect Parts
 Is there a selection of parts in front of the operator that
would allow for the wrong part to be chosen and
assembled?

Slide 81
Error Proofing Techniques
 Incorrect
Incorrect Parts
Parts
Is there a selection of parts available
Is there a selection of parts available
at the workstation?
at the workstation?
Are similar parts assembled onto the Implement operator instructions,
Are similar parts assembled onto the
product at the same location? NO visual aids and training as minimum
product at the same location?
requirement

YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process?
in design of product/process?
(Consolidation, separate operations)
(Consolidation, separate operations) YES
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?

NO
What can be done to detect whether
What can be done to detect whether Implement Error Proofing
the incorrect part has been
the incorrect part has been (process/design change and/or
assembled?
assembled? detect/lock out device)
Detection device - bar code,
Detection device - bar code,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch

Lock out subsequent operation if the

Lock out subsequent operation if the
incorrect part is detected
incorrect part is detected
Lock out device - limit switch,
Lock out device - limit switch,
conductivity sensor...
conductivity sensor...

Slide 82
Error Proofing Techniques
 Brainstorm Error Proofing Mechanism

Incorrect Parts- Thought Starters

• Make visible/obvious if incorrect part
° Color code - match part to product
° Visible at numerous operations and pack
° Position of part as moves down line
° Visual aid/picture posted with correct part present and highlighted
• Redefine process
° Assemble early in process
° Successive check
° Rearrange multiple write-up to separate assembly of like parts
• Monitor part supply
° Only supply parts needed for that model
• Sensors
° Photoelectric eyes to detect, lock out until corrected
° Limit switch to detect, lock out until corrected
• Modify/design fixture
° Unable to assemble incorrect part
• Modify design
° Eliminate part
° Prevent assembly of incorrect part
Slide 83
Error Proofing Techniques
 Error-Proofing Process
“Quick Response / Quick Implementation”
Candidates for Error Proofing

First Time
Systematic Departmental
Quality Internal Customer
Problem Containment Warranty
(F.T.Q.) Plant Rejects
Solving Station Information
at Audit (PPM)
Process Network
Operation
Institutionalize
the Solution
and the Ongoing
Control
Continuous
Institutionalize Opportunity
Improvement
Problem Solving Documentation

Prevent Select
5. Evaluate 1. Identify

The Error Proofing Process:

People
– Utilizes a multi-functional approach &
– Is driven by Customer Satisfaction and allows for Quick 4. Implement
Teamwork
2. Analyze
response and implementation of solutions
– Is used to “Kill” problems
3. Plan
– Is documented in the ‘Problem Solving Document’ (PSD)
Correct Contain
– Supports Continuous Improvement Methodology
– Is the ‘Contain’ step in the 5 Step Problem Solving Process

Slide 84
Error Proofing Techniques
 1% DEFECT RATE (99% YIELD)
OF ALL STATIONS
1% 1%
Defect Defect
Rate 1% Rate 1%
1% 1%
Defect Defect
Defect Defect
Rate Rate
Rate Rate
Cell 1 Cell 2
1% 1% 1% 1%
Defect Defect Defect Defect
Rate Rate Rate Rate

1% 1%
Defect Defect
Rate 1% Rate 1%
1% 1%
Defect Defect Defect Defect
Rate Rate Rate Rate
Cell 4 Cell 3
1% 1% 1% 1%
Defect Defect Defect Defect
Rate Rate Rate Rate

RESULTS IN 78%
CONFORMING PRODUCTS Slide 85
Error Proofing Techniques
 PROCESS FALLOUT TABLE
Centered Process

Process capability ratio Parts per million defective

0.50 133,600.00
0.75 24,400.00
1.00 2,700.00
1.10 967.00
1.20 318.00
1.30 96.00
1.40 26.00
1.50 6.80
1.60 1.60
1.70 0.34
1.80 0.06
2.00 0.0018

Slide 86
Error Proofing Techniques
 DIDN’T
DIDN’TWASH
WASH
HANDS
HANDS

Slide 87
Error Proofing Techniques
 ERROR PROOFING
Implementation Procedure:
• Product Tooling Design Phase
¶ Predict Potential Quality Defects during
Product Tooling Design Stage.
 Use DFM to modify Tooling Design to
Prevent Potential Defects from Occurring in
Production based on Potential Defects
Identified.
 Build Poka-Yoke Devices into the Process
where Design “Fixes” can not be
Incorporated.

Slide 88
Error Proofing Techniques
 ERROR PROOFING
Implementation Procedure (Continued):
• Production Phase
¶ Retro-fit Poka-Yoke Devices into Existing
Tooling
 Use Quality History to Target Potential Error

Proofing Application Sites

Obtain Set-Up Operator Input as to Where to

Apply “Error Proofing” Devices as well as

the Type of Devices to Use.

Slide 89
Error Proofing Techniques
 ERROR PROOFING
Some Error Proofing Guidelines:
• Standardize Press Shut Heights
• Utilize Digital Process Parameter Gages
• Apply Locating Devices to Dies, Fixtures, Etc.
• Gages Pre-calibrated prior to Start of Set-Up
• Utilize Common/”Quick Connect Fittings and
Clamping Hardware
• “One Way” Loading
• 100% Component Presence Check
• Verify “Machine Cycle Completed”
• Detected “Error” Stops Process
Slide 90
Error Proofing Techniques
CASUAL CONNECTIONS BETWEEN DEFECTS AND HUMAN ERRORS

Strongly Connected Connected

Misunderstanding

Non-Supervision
Misidentification
Human

International
Errors

Inadvertent
Amateurs

Slowness

Surprise
Forgeful
Causes

Willful
of Defects

Omitted Processing
Processing Errors
Errors Setting Up Workpieces
Missing Parts
Wrong Parts
Processing Wrong Workpiece
Misoperation
Adjustment Error
Improper Equipment Setup
Improper Tools and Jigs
SOURCE: NKS/Factory Magazine “Poka-Yoke”
Slide 91
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES

WORKSHOP OBJECTIVE

To improve the PROCESS by helping

people prevent ERRORS and increase the
chances of DETECTION, so that FAILURE
MODE occurrences are
ELIMINATED.

Slide 92
Error Proofing Techniques
 Workshop Action Items
Supplier: Location:

GM Buyer: Creativity Team:

Activity Type: SDE:

Activity Date: Follow up Dates: -

No. Action Item Responsibility Target Progress

Date Comments

Slide 93
Error Proofing Techniques
 Error Proofing Technique Workshop
SUMMARY OF RESULTS

DATE OF WORKSHOP:_________________
SHORT TERM F/U DATE:_______________

LONG TERM F/U DATE:________________

SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:___________________________________________________________________
PROCESS:_________________________________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:___________________________________________________________

AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST

_________________
ACTUAL

FIRST TIME
QUALITY
FORECAST

_________________
ACTUAL

PROCESS
CAPABILITY
FORECAST

_________________
ACTUAL

OVERALL QUALITY
MEASURE
FORECAST

_________________
ACTUAL

COMMENTS:

Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.

TEAM LEADERS:

PHONE:

© 1995 Copyright General Motors. All rights reserved.

Slide 94
Error Proofing Techniques
WHAT IS NECESSARY TO BE
SUCCESSFUL?

• Management Support
• Team Members who:
• Are team players
• Communicate well
• Not afraid to contribute
• Are empowered
• Have the desire to solve problems
• Can make it happen

Slide 95
Error Proofing Techniques
 Error Proofing Techniques

TEAM RECOMMENDATION

KEY AREAS:
• OPERATORS & INSPECTORS FROM STUDY
AREA
• PROCESS AND DESIGN ENGINEER
• QUALITY REPRESENTATIVE
• SKILLED TRADES

• MANAGEMENT REPRESENTATIVE - MIDDLE

TO UPPER LEVELS
• MANUFACTURING REPRESENTATIVE

OPTIONAL AREAS:
• MAINTENANCE REPRESENTATIVE

• OTHER TECHNICAL REPRESENTATIVES:

• INDUSTRIAL ENGINEER
• UNION REPRESENTATIVE

Slide 96
Error Proofing Techniques
 Error Proofing Techniques
TEAM MEMBERS DESIRED BACKGROUND

 KNOWLEDGE AND EXPERIENCE OF THE PROCESS BEING

STUDIED.

 POSSESSING A TEMPERAMENT TO WORK IN TEAMS AND

CONTRIBUTE TO TEAM GOALS.

 WILLING TO MAKE CHANGE AND THINK BEYOND NORMAL

PRACTICES.

 EMPOWERED TO SPEAK FOR ORGANIZATION AND

KNOWLEDGEABLE TO WHOM TO REACH FOR CRITICAL
DECISIONS OR ANSWERS TO QUESTIONS.

 INNOVATIVE AND CREATIVE THINKING PROCESS.

 ABILITY TO REPRESENT AND CONVEY ATTITUDES OF AREA

/ FUNCTION REPRESENTED.

 AWARE OF INDUSTRY AND COMPANIES COMPETITIVE

SITUATION, AND NEED TO CHANGE.

 UNDERSTAND AND ACCEPT THAT THE WORKSHOP

PROCESS MAY INVOLVE LONG HOURS.

Slide 97
Error Proofing Techniques
 SUGGESTED INFORMATION
FOR REVIEW
• PFMEA Data
• Internal Audit Information
• Control Plan
• Process Flow
• Root Cause Analysis Performed to Date
• Process Capability
• Customer Rejections/Warranty Information
• Scrap Rate Information by Cause
• Poka-Yoke Devices
• Other?

Slide 98
Error Proofing Techniques
 CHECKLIST

STATUS ITEM
CONFERENCE ROOM-KICKOFF MEETING DAY ONE, TIME TBD, LARGE ENOUGH FOR TEAM MEMBERS, STAFF, AND VISITORS.
- TRANSPARENCY PROJECTOR
- VHS TAPE MACHINE
- EASEL WITH MARKERS
CONFERENCE ROOM-WRAP-UP MEETING LAST DAY, TIME TBD, LARGE ENOUGH FOR TEAM MEMBERS, STAFF, AND VISITORS.
- TRANSPARENCY PROJECTOR
- VHS TAPE MACHINE
- EASEL WITH MARKERS
CONFERENCE ROOM-FOR EACH WORKSHOP TEAM FROM DAY ONE TILL LAST DAY LARGE ENOUGH FOR UP TO 15 PEOPLE.
- TRANSPARENCY PROJECTOR
- EASEL WITH MULTI-COLORED MARKERS AND PLENTY OF EASEL PAPER
- VHS TAPE MACHINE
- MASKING TAPE
- LAYOUT OF ROOM CONDUCIVE TO GOOD TEAM INVOLVEMENT (NOISE, FURNITURE CONFIGURATION, TEMPERATURE CONTROL).
- ACCESS TO COPY MACHINES FOR COPIES AND TRANSPARENCIES.
- LOCATION CLOSE TO WORKSITE FOR IMPLEMENTATION WORKSHOP.
- BLANK TRANSPARENCIES AND MARKERS AVAILABLE.
BREAKOUT ROOM(S)-FOR WORKSHOP TEAM TO MEET IN SUBGROUPS AT VARIOUS TIMES.
WORKSHOP TEAM MEMBERS SELECTED.
PARTICIPANT REVIEW OF PROCESS AND PURPOSE/EXPECTATIONS (GM TO ASSIST?).
WORKSITE AND AFFECTED AREA REVIEW OF WORKSHOP PLANS AND PURPOSE/EXPECTATIONS (GM TO ASSIST?).
MESSAGE CENTER ARRANGEMENT ESTABLISHED FOR PARTICIPANTS AND VISITORS,
NAME TAGS FOR EACH TEAM MEMBER (NOT STICK ON TYPE).
REFRESHMENTS FOR MORNING AND AFTERNOON (COFFEE, POP, FRUIT, WATER) FOR TEAMS AND KICKOFF MEETING.
LUNCH ARRANGEMENTS TO MINIMIZE TRAVEL TIME (IF PRESET MENU, KEEP ON LIGHT SIDE).
PARTICIPANT MATERIALS AVAILABLE.
- WRITING PAD & PEN
- SAFETY EQUIPMENT
- WORKSHEETS (GM TO PROVIDE)
- CLIPBOARD OR HARD WRITING SURFACE
OTHER ATTENDEES FOR KICKOFF AND WRAP-UP MEETING IDENTIFIED.

Page 1 of 2
 CHECKLIST

STATUS ITEM
WORKSHOP WORKSITE INFORMATION PROVIDED/AVAILABLE:
- PLANT LAYOUT OF WORKSITE AREA SHOWING PRODUCT FLOW AND OPERATORS (ON 8 1/2 X 11 PAPER).
- CUSTOMER SPECIFICATIONS AND REQUIREMENTS.
- EQUIPMENT PROCESS CAPABILITY AND PERFORMANCE RECORDS AVAILABLE.
- INTERNAL PLANT AUDIT INFORMATION.
- CUSTOMER REJECTIONS BY TYPE AND CAUSE
- REJECTION RATE (IN-PROCESS SCRAP)
- SETUP REQUIREMENTS (PEOPLE & TIME)
- CHANGEOVER TIME
- EQUIPMENT DOWNTIME OR UPTIME
- PFMEA DATA
- PROCESS FLOW INFORMATION AND CONTROL PLAN DATA
DRESS CODE ESTABLISHED AS CASUAL PLUS PLANT SAFETY REQUIREMENTS (E.G. HARD SOLE SHOES, LONG SLEEVES, ETC).
TRANSPARENCY DESCRIBING ADMINISTRATIVE DETAILS:
- LAYOUT AND LOCATION OF CONFERENCE ROOMS.
- REST ROOM LOCATIONS.
- LUNCH ARRANGEMENTS
- LIST OF ATTENDEES/PARTICIPANTS BY NAME, COMPANY, AND TITLE
- SAFETY REQUIREMENTS
- MESSAGE CENTER(S)
- PHONE LOCATIONS
- SMOKING REGULATIONS (NO SMOKING IN CONFERENCE AND TEAM ROOMS REQUESTED)
FINALIZE OPENING KICKOFF SPEAKER IDENTIFICATION, TIMING, AND CONTENT.
MTG ARRANGED FOR END OF EACH DAY WITH TOP MANAGEMENT AND TEAM LEADERS TO REVIEW STATUS/ADDRESS ROADBLOCKS.
LOGISTIC ARRANGEMENTS MADE TO ALLOW GM PERSONNEL TO DRIVE DAILY ON PLANT PROPERTY TO WORKSITE/MEETING ROOMS.

Page 2 of 2
 ERROR PROOFING TECHNIQUES
ATTENDEES
NAME COMPANY CURRENT JOB ASSIGNMENT BUSINESS PHONE

Slide 101
Error Proofing Techniques
 Workshop Action Items
Supplier: Location:

GM Buyer: Creativity Team:

Activity Type: SDE:

Activity Date: Follow up Dates: -

No. Action Item Responsibility Target Progress

Date Comments

Slide 102
Error Proofing Techniques
 Error Proofing Technique Workshop
SUMMARY OF RESULTS

DATE OF WORKSHOP:_________________
SHORT TERM F/U DATE:_______________

LONG TERM F/U DATE:________________

SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:___________________________________________________________________
PROCESS:________________________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:___________________________________________________________

AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST

_________________
ACTUAL

FIRST TIME
QUALITY FORECAST

_________________
ACTUAL

PROCESS
CAPABILITY FORECAST

_________________
ACTUAL

OVERALL QUALITY
MEASURE FORECAST

_________________
ACTUAL

COMMENTS:

Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.

TEAM LEADERS:

PHONE:

Slide 103
Error Proofing Techniques
 DEFINE CURRENT STATE
• AREAS OF INVESTIGATION AND CONFIRMATION:

• PROCESS FLOW DIAGRAM

• REVIEW OF PROBLEM AREA
• PFMEA
• INTERNAL AUDITS AND INFORMATION
• ROOT CAUSE ANALYSIS EFFORTS TO DATE
• CUSTOMER REJECTIONS
• CONTROL PLANS

• COMPLETE “SUMMARY OF RESULTS” CURRENT STATE

Slide 104
Error Proofing Techniques
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA) FMEA Number ________________________________
Page _________ of ___________________________
Item________________________ Process Responsibility______________________ Prepared by __________________________________
Model Year(s) / Vehicle(s)_______________________Key Date________________________________ FMEA Date (Orig.)________________ (Rev.)________
Core Team______________________________________________________________________________________________________________________________________________________________
9 10 11 12 13 14 15 16 17 18 19 20 21 22

Process C O D Action Results

Function l Potential c e
Potential Potential S a Cause(s)/ c Current t R. Responsibility S O D R.
Failure Effect(s) E s Mechanism(s) u Process e P. Recommended & Target Actions e c e P.
Requirements Mode of Failure V s of Failure r Controls c N. Actions Completion Date Taken v c t N.

EPFORM-L.PPT Pg.1
02/13/00
 Workshop Action Items
Supplier: Location:

GM Buyer: Creativity Team:

Activity Type: SDE:

Activity Date: Follow up Dates: -

No. Action Item Responsibility Target Progress

Date Comments
 ERROR PROOFING CONTROL
Potential Error EP # Error Proofing Mechanism LevelPLAN
of Install Operator Process Audit
Control Date Instruct. # Method Frequency Responsible
 Error Proofing Techniques SUMMARY OF
DATE: __________
SHORT TERM F/U DATE:________

RESULTS LONG TERM F/U DATE:_________

SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:_____________________________________________________________
PROCESS:________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:_____________________________________________________

AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST

_________________
ACTUAL

FIRST TIME
QUALITY FORECAST

_________________
ACTUAL

PROCESS
CAPABILITY FORECAST

_________________
ACTUAL

OVERALL QUALITY
MEASURE FORECAST

_________________
ACTUAL

COMMENTS:

Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.

TEAM LEADERS:

PHONE:
 WHAT IS
ERROR
PROOFING?

HOW AND
WHERE DO WE
APPLY IT?

Slide 109
Error Proofing Techniques
 WHAT IS ERROR PROOFING?

Error
ErrorProofing
Proofingis
isthe
theactivity
activityof
ofawareness,
awareness,detection,
detection,and
and
prevention
preventionof
oferrors
errorswhich
whichadversely
adverselyaffect:
affect:
Our
Ourcustomers
customers (defects)
(defects)
Our
Ourpeople
people (injuries)
(injuries)
and
andresult
resultin
inWASTE!
WASTE!

Awareness: Having the forethought that a mistake can be made, communicating the potential, and
planning the design of the product or process to detect or prevent it.

Detection: Allowing the mistake to happen but providing some means of detecting it and alerting
someone so that we fix it before sending it to our customer.

Prevention: Not allowing the possibility for the mistake to occur in the first place.

Slide 110
Error Proofing Techniques
WHY DO WE SUGGEST ERROR PROOFING?

PURPOSE OF ERROR PROOFING EFFORT:

• Drive simple and inexpensive devices into our
processes to help people notice errors

KEY CONCEPTS / ASSUMPTIONS:

• People want to do a good job
• People make mistakes
• An error only becomes a defect if it’s passed on
• The only way to notice errors is to have devices
do 100% inspection (not people)

Slide 111
Error Proofing Techniques
 SOURCES OF DEFECTS
 OMITTED PROCESSING
 PROCESSING ERRORS
 ERRORS SETTING UP WORKPIECES
 MISSING PARTS
 WRONG PARTS
 PROCESSING WRONG WORKPIECE
 MISOPERATION
 ADJUSTMENT ERROR
 EQUIPMENT NOT SET UP PROPERLY
 TOOLS AND JIGS IMPROPERLY PREPARED

Slide 112
Error Proofing Techniques
DIFFERENT KINDS OF ERRORS
 FORGETFULNESS
 ERRORS DUE TO MISUNDERSTANDING
 ERRORS IN IDENTIFICATION
 ERRORS MADE BY AMATEURS
 WILLFUL ERRORS
 INADVERTENT ERRORS
 ERRORS DUE TO SLOWNESS
 ERRORS DUE TO THE LACK OF STANDARDS
 SURPRISE ERRORS
 INTENTIONAL ERRORS

Slide 113
Error Proofing Techniques
 FIVE TYPES OF
DEFECT OCCURRENCES
1. INAPPROPRIATE STANDARD OPERATING
PROCEDURES OR METHODS.

2. TOO MUCH VARIABILITY IN ACTUAL

OPERATIONS EVEN THOUGH STANDARD
METHODS ARE APPROPRIATE.
(CARRY OUT PROPER MAINTENANCE BEFORE OPERATIONS
BEGIN)

3. DAMAGED MATERIALS OR EXCESSIVE

VARIABILITY IN THICKNESS.
(USE APPROPRIATE MATERIALS AND INSPECT CAREFULLY ON
RECEIPT)

Slide 114
Error Proofing Techniques
FIVE TYPES OF DEFECT OCCURRENCES

4. WORN MACHINE BEARINGS OR

TOOLS
(CARRY OUT THOROUGH MAINTENANCE AND TOOL
MANAGEMENT)

5. SIMPLE MISTAKES OR
IMPERFECTLY CONTROLLED TASK
EXECUTION

Slide 115
Error Proofing Techniques
 ZERO QUALITY CONTROL
COMPONENTS
• SOURCE INSPECTION:
• Checks for factors that cause errors, not the resulting defect.
(Locator pin)

• 100% INSPECTION:
• Uses inexpensive Poka-Yoke devices to inspect automatically
for errors or defective operating conditions. (Limit switch).

• IMMEDIATE CORRECTIVE ACTION:

• Operations are stopped instantly when a mistake is made and
not resumed until it’s corrected. (Machine is shut down)

• RECOGNIZE THAT PEOPLE ARE HUMAN AND USE

POKA-YOKE DEVICES TO FULFILL “CHECKING
FUNCTIONS”.

Slide 116
Error Proofing Techniques
 SOURCE INSPECTION
MANAGEMENT CYCLE
CAUSE
4. These are multiple RESULT
assembly operations.
1. Shingo wants to set-up
many of these small
circles.

Defect
Error (small cycle)

Conventional Defect
Management Cycle
Check (large cycle)
Action and 3. Shingo wants to
discourage these
feedback or make shorter.
Check
Action and
feedback

2. View these as one 5. This is an end of line

operator’s station. inspection station.
Slide 117
Error Proofing Techniques
 ERROR PROOFING
Techniques
• Design for Manufacturability
• “Poka-Yoke” System Devices

Slide 118
Error Proofing Techniques
 ERROR PROOFING
Techniques:
• Design For Manufacturability
(DFM)
Technique that Results in Designs that
Cannot be Incorrectly Manufactured or
Assembled. This Technique can also be
used to “Simplify” the Design and therefore
reduce it’s cost.

Slide 119
Error Proofing Techniques
DESIGN STAGE - BEST OPPORTUNITY TO
IMPACT QUALITY & COST

CHANCES FOR
QUALITY & COST COST TO
IMPROVEMENTS IMPLEMENT

COST

TIME START OF PRODUCTION

Slide 120
Error Proofing Techniques
ERROR PROOFING TECHNIQUES
DESIGN PREVENTS
MISASSEMBLY

Slide 121
Error Proofing Techniques
 ERROR PROOFING
Techniques (Continued)
• “Poka-Yoke” System*
Set-Up Devices or Inspection Techniques
that Assure that Set-Up is Done Correctly;
i.e. Produces 100% Good Parts from the
First Piece on

“Zero Quality Control: Source Inspection and the Poka-Yoke System” -

Shigeo Shingo; 1986

Slide 122
Error Proofing Techniques
 ERROR PROOFING TECHNIQUES
ERROR PROOFING THE
PROCESS
Problem: Missing Weld Nuts
Welding Machine

• Automatically
Up Up
Stops Process
• Provides Visual
Down Down
Height of Nut
& Audio Control
Nut
Product

Slide 123
Error Proofing Techniques
 Effective Error Proofing
techniques can reduce or
eliminate our dependence on
operator knowledge and
vigilance, therefore reducing
the number of defects we
send to our customers!!

Slide 124
Error Proofing Techniques
 Levels of Error Proofing

No Controls Instructio Training / Visual Containment* Defect Detection Avoidance

n Visual Controls - 100% - Stops Process - Robust
Aids Inspect Product /
Process
Designs
- Autonomation

AWARENESS DETECTION PREVENTION

* 100% inspection for containment of a defect should be implemented only as a temporary fix, as it, too, is subject
to operator vigilance.

Slide 125
Error Proofing Techniques
BASIC FUNCTIONS OF A
POKA-YOKE SYSTEM

• SHUTDOWN

• CONTROL

• WARNING

Slide 126
Error Proofing Techniques
 DETECTION DEVICES FOR
POKA-YOKE SYSTEMS
 CONTACT DETECTION DEVICES

 NON-CONTACT DETECTION DEVICES

 DEVICES THAT DETECT PRESSURE,

TEMPERATURE, ELECTRIC CURRENT,
VIBRATION, CYCLES, TIME, TIMING AND
INFORMATION TRANSMISSION

Slide 127
Error Proofing Techniques
CONTACT DETECTION DEVICES
 LIMIT SWITCHES

 MICRO SWITCHES

 TOUCH SWITCHES

 DIFFERENTIAL
TRANSFORMERS

 TRIMETRONS

 LIQUID LEVEL RELAYS

Slide 128
Error Proofing Techniques
NON CONTACT DETECTION DEVICES
 PROXIMITY SWITCHES
 PHOTOELECTRIC SWITCHES
 BEAM SENSORS
 FIBER SENSORS
 AREA SENSORS
 DIMENSION SENSORS
 DISPLACEMENT SENSORS
 METAL PASSAGE SENSORS
 COLOR MARKING SENSORS
 DOUBLE-FEED SENSORS
 WELDING POSITION SENSORS
 TAP SENSORS
 FLUID SENSORS

Slide 129
Error Proofing Techniques
FIVE BEST POKA-YOKE
1. GUIDE PINS OF DIFFERENT SIZES

2. ERROR DETECTION AND ALARMS

3. LIMIT SWITCHES

4. COUNTERS

5. CHECKLIST(S)

Slide 130
Error Proofing Techniques
 Where Poka-Yoke Incorporate
is technically Poka-Yoke
or economically functions
unfeasible in into successive
self-check system... check systems.

Slide 131
Error Proofing Techniques
EXAMPLES OF ERRORS AT WORK
...
• Missing Parts
° Forgetting to assemble a part - screws, labels, orifice tubes...

• Misassembled Parts
° Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...

• Incorrect Processing
° Disposing of a part rejected at test to the wrong pile

• Incorrect Parts
° Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...

Slide 132
Error Proofing Techniques
PROBLEM STATEMENT

LOST

Slide 133
Error Proofing Techniques
WHAT IS THE ROOT CAUSE????

Slide 134
Error Proofing Techniques
PROBLEM SOLVING PROCESS
For Customer Satisfaction

Continuous
Institutionalize Opportunity
Improvement

Prevent Select
5. Evaluate 1. Identify

People
&
Teamwork
4. Implement 2. Analyze

3. Plan
Correct Contain

Slide 135
Error Proofing Techniques
 Identify Error Proofing Opportunities
• PFMEA
IDENTIFY • Quality Data, PR/R, Warranty Data...
• Brainstorm (Questions to Ask, Free Form...)

Prioritize Opportunities (RPN, Pareto...)

Determine Level of Error Proofing

HOW
HOW
ANALYZE Brainstorm Error Proofing Mechanisms
• Build on past experience
• Can use more than one mechanism
TO
TO Select Error Proofing Mechanism
• Most cost effective
• Simple
ERROR
ERROR Plan (Process Mechanisms)
PLAN • Action plan
• Error Proofing Control Plan (EPCP)
PROOF
PROOF Implement Error Proofing Mechanism
•Installation
IMPLEMENT •Validation
• EPCP
•Check sheet/Log
•Operator Instructions

EVALUATE Evaluate Results

Slide 136
Error Proofing Techniques
 TEAM PROCESS
STEP:
1. IDENTIFY FAILURES
PRIORITIZE FAILURES
SELECT ONE
DOCUMENT CURRENT CONDITION

2. ROOT CAUSE ANALYSIS

WHY - WHY
FLOOR REVIEW
INVESTIGATION

3. BRAINSTORM ERROR PROOF DEVICES

SELECT BEST IDEAS
PLAN IMPLEMENTATION

4. IMPLEMENT IDEAS
COMPLETE BEFORE AND AFTER DOCUMENT

5. COMPLETE FUTURE ACTION PLANS

DOCUMENT NEW CONDITION

SELECT NEXT FAILURE AND BEGIN STEP 1

Slide 137
Error Proofing Techniques
 TOOLS FOR ANALYSIS
Flow Chart Fishbone Diagram Pareto Chart

Problem

Histogram 5 Why’s Run Chart

Problem
Why
Why
Why
Why
Why
Root Cause

Scatter Plot Control Chart Pictograph

Slide 138
Error Proofing Techniques
 IMPLEMENTATION
• TRY DIFFERENT IDEAS
• Error Proofing Device / Tool
• New Containers
• Different Process (ask Employees to try)
• Different Flow of Materials
• Detection of Defects
• Re-route

• CALL SOMEONE
• Packaging
• Design Changes
• Layout Changes
• Approvals from Division

• PAPERWORK
• Write P.M. Process
• Re-Write Process Steps
• Purchase Order
• Revise / Revised Layout
Slide 139
Error Proofing Techniques
 OSBORN’S RULES FOR

BRAINSTORMING

• Criticism Forbidden
• Freewheeling Encouraged
• Quantity (Going for a lot of ideas)
• Combine and Expand - Hitch-hiking

Slide 140
Error Proofing Techniques