IE-673104 TOTAL QUALITY MANAGEMENT

MIDTERM- Human Error Detection and Prevention.

Submitted by: Tejas A Gaonkar

Date: 3/29/2015

1. Coding error by human due to lack of knowledge

Detection:
One quality error which I experienced was while using an application from Android Play
store which used to crash or sometimes used to take longer time to load although I had
sufficient free memory on my mobile platform.

Figure1.Upgarded app with new features

Prevention:
In order to resolve this error I had to write review about the error occurring on the User
Rating portal provided by Play store.

Figure2. User review portal

After few weeks an updated version of that application was launched addressing the
issues, the bugs were fixed and additional features were added in the application which
improved memory management.
2. Quality defect occurring due to lack of planning for unexpected issues.
Detection:
While working at a manufacturing plant we faced issues to carry out the CED (Cathodic
Electro Deposition) Process on our Automotive Load Bodies in order to make them
corrosion resistant.

Figure3. Automotive Load Bodies before coating

Figure4. Automotive Load Bodies after coating

This CED process involves immersing the entire metal body which is electrically grounded
into the series liquefied chemical tanks which contain positively charged ions due to the
direct current passed through them so that a thin layer of chemical is deposited on the
metal surface.
The quality defect which we observed was that few sections of the automotive load body
were not coated with the CED paint due to formation of air bubbles when the body was
immersed inside the liquefied chemical tanks.
Prevention:
The solution for this problem was to change the position by varying the angle of
inclination for automotive Load bodies while immersing them inside the liquefied
chemical tanks and the other solution was to make small holes on the sections which
were not coated due to formation of air bubbles.
3. Error occurring due to lack of knowledge
Detection:
While designing PCB (Printed Circuit Boards) using software tools like Eagle for making
wireless communication possible between the transmitter (Remote Controller) and
receiver installed on a land rover which will facilitate the forward, backward, left and right
motion of the mobile platform i.e. roverbot if the Electronic Engineer selects electronic
components such as capacitor, resistors, inductors, transistors of wrong value/rating
then it will result in undesired outcome and many times the circuit will not function and
signals will not be transmitted wirelessly.
Prevention:
The only way to avoid this error is that the designer should be a domain expert and should
be well versed with the characteristics of active or passive elements being used in the
electronic circuit. He should simulate the circuit to check the functionality of various
electronic circuits involved and then he should go ahead with the implementation.
4. Improper furnishing of door lock

Figure5. Unfurnished door lock

Detection:
This picture too was taken in my own house. Here we can see that the carpenter who
installed the lock didnt have any idea what to do or we can say that he was not at all
skilled. He as drilled multiple holes to fix the lock in turn as damaged the entire wooden
block and more so over it looks so ugly. We can see that the paint too as come out and
there are sharp edges on the wooden block. This can cause a serious problem to the
people who are staying. Say someone was trying to open the door and by mistake his
fingers get entangled in the sharp edges of the wooden block then he might be seriously
injured.
Prevention:
Firstly a well skilled worked as to be employed while doing such work. Before starting the
work the person has to measure the dimensions properly so that he need not drill multiple
holes making it look ugly. After finishing the work he as to paint the remaining part of
the lock so that the dirt accumulated near it doesnt stay. The carpenter as to use a high
quality drilling machine so that cracks on the wooden block doesnt occur. Use of chisel
is highly recommended.
5. Error in interpreting mathematical data
Detection:
Mechanical Engineer or Draftsmen working on Solid works creates something which is
not feasible as he was not able to interpret the key design parameters as required in the
machine part.
Prevention:
As a design engineer he should be well acquainted with three dimensional view of the
part which will help him in analyzing and implementing the appropriate design
parameters of the component.
6. Food cupboard opening

Figure6. Kitchen cupboard segregation

Detection:
Cabins used for storing ingredients generally have numerous numbers of blocks. These
things are places in different spots at different times and a lot of time is invested in
searching for the required things. Most of the time users forget where they have placed
what. So when there is an emergency to cook something people tend to use the wrong
ingredients. Avoiding this loss of time will help reduce time and preventing wrong
ingredients being used.
Prevention:
Display that show what is kept in which part of the cabin with the help of sensors. A
voice activated command that prompts the cabinets to speak out the ingredients. This
can be integrated with the main system in the smart homes and relay it to the mobile
device that the owner wants to help in shopping if required. When the user places an
item inside the cabin then there should be an option to enter what item is placed, so
that when he wants some items he can digitally get to know were exactly he as placed
it. This will make sure wrong ingredients are not used for the right dish.
7. Nave Error
Detection:
Many a times we observe at work place that a person can do a work in 5 days but the
same work can be done by some other guy in 2 days utilizing the same resources as
required by the guy doing the task in 5 days so we can say that the efficiency of work is
affected significantly. It depends upon the experience, technical acumen, dedication and
practice of the individual performing the task.
Prevention:
To prevent this issue we should assign the work to a proper skillful person so that
efficiency of work is ensured. We need to have a proper screening process which will help
us in identifying the candidate with conducive skill sets, knowledge and interest level.
Selection process should include technical, behavioral and social rounds for filtering the
candidates.
8. Memory based lapse forgetting the steps involved in a job
Detection:
It is necessary to follow step by step procedure to get the desired result so if we forget/skip
a step then we wont be able to complete the process successfully. Eg. While assembling
a motorbike we need to follow the sequence of assembling the components if we miss to
place a part (Component) then we have to start the procedure from the beginning itself.
Prevention:
In order to prevent this error we need to make a documentation of the key steps involved
in assembling process with detailed procedure and graphical representation as required.
One must strictly abide by the Standard operating procedure which is drafted by
professionals in instruction manual.

9.

Heating Pipe Exposed

Figure7. Damaged outer coating of a gas pipe

Detection:
The above picture is taken in my house, which clearly illustrates the negligence in
maintaining the house and neglecting the safety of the tenants living in it. This can be
seen visually by our naked eye. During winter, when the heaters are widely used at high
temperature, the opening as shown in the figure can cause serious burns and other
damages, like burnt electrical wires, the carpet etc. This issue has been raised several
times by many tenants living in this house prior to me but the action hasn't been taken.
If something gets burnt and catches fire, the consequences faced by the tenants as well
as the people staying close by is far by out of reach giving everyone sleepless nights.
Prevention:
There should be a proper inspection of the work which has been done when
manufacturing or doing the electrical works in a house or any other works in
manufacturing units. The small issues like these look to be small, if ignored, they are
capable of doing some big and real damages which cant be expected. Lack of commitment
of work by the worker who have done this and the inspection which has been done by the
inspection inspector. There should be a proper and dedicated team and workers involved
and dedication to the work for the safety of the users is to be given the top priority.
10. Error arising due to fatigue and burden of work.
Detection:
Worker in an manufacturing unit is sometimes given an extension even though he had
been working from past 10 hours then due to the stress, tiredness he wont be able to
perform to the best of his abilities and he wont be able to give attention to minute details

as his frame of mind wont be willing to work thus deteriorating the quality of job or work
being performed by that individual.
Prevention:
In order to prevent this we should allocate proper work hours and sufficient leisure time
to break the monotonous work routine of the employees which will keep them mentally
fresh and rejuvenated.
11. Deliberately doing things in a wrong way not complying with the process/rules.
Detection:
In recent times we have witnessed employees going on a strike due to conflict of interest
or when their demands are not fulfilled by the management of the organization thereby
effecting the production resulting in loss.
Prevention:
To avoid this we need to understand the needs and demands of the workers by amicably
discussing the problems faced by them to resolve the issue and identifying the real politics
behind the strike.
12. Work environment not good for workers
Detection:
Sometimes we observe that surrounding areas or working conditions are not favorable to
employees which might make them uncomfortable at work losing their precision and
focus on the work assigned.

Figure8. Ideal Workplace

Prevention:
The working environment i.e. surrounding areas should be pleasant (neat, clean and
hygienic) and well equipped with proper amenities so that the employees feel convenient
and concentrate on the work assigned to them.
13. Error occurring due to Parallax

Detection:
A Site Engineer miscalculates the dimensions due to parallax while taking readings at a
construction site which will result in improper construction work consuming lot of
resources such time, money and labor.

Figure9. Site Engineer measuring height using optical leveling tool

Prevention:
To avoid this error the Site Engineer should be well aware about the job in hand and
should tally the readings with actual data in hand. Appropriate measurement tool must
be selected while taking the readings. The measurement tool must be well calibrated and
should be handled with care.