Manufacturing Systems Error Proofing

Error Proofing
Section 3:

Problem Solving Process

Problem Solving Process

For Customer Satisfaction
Institutionalize

Continuous
Improvement Prevent
5. Evaluate 1. Identify

Opportunity

Select

People & 4. Implement Teamwork 2. Analyze

Correct

3. Plan

Contain
15147 ig3b.ppt Rev 28-Jan-00 113

Identify Error Proofing Opportunities

Identify

PFMEA Quality Data, PR/R, Warranty Data... Brainstorm (Questions to ask, free form...)

How To Error Proof

Prioritize Opportunities (RPN, Pareto...) Determine Level of Error Proofing

Analyze

Brainstorm Error Proofing Mechanism

Most cost effective Simple

Plan (Process Mechanisms)

Plan

Action plan Error Proofing Control Plan (EPCP)

Implement Error Proofing Mechanism

Implement Evaluate

Installation

Check Sheet/Log

Validation
EPCP

Operator Instructions

Evaluate Results

Manufacturing Systems Error Proofing

Error Proofing Process Steps:

Step 1: Identify failures

Prioritize failures
Select one Document current condition Step 2: Root cause analysis 5 whys Floor Review Investigation

Continue

Manufacturing Systems Error Proofing

Error Proofing Process Steps:

Step 3:
Brainstorm different process control schemes, methods, error

proofing devices, and / or design features modification

Select best ideas Conduct cost vs. benefits analysis for each idea Plan implementation

Step 4:
Implement ideas Complete before and after document

Step 5:
Complete future action plans Document new condition

Select next failure and begin step 1

Manufacturing Systems Error Proofing

Implementation
Try different ideas
New containers Different methods (ask employees to try) Different flow of methods

Detection of defects
Re-route Different process

Different process control plan Continue

Manufacturing Systems Error Proofing

Implementation (continued)
See your advisor or supervisor (evaluation / implementation resources)
Materials management Industrial engineering Mechanical engineering Health and safety Ergonomics Continue

Manufacturing Systems Error Proofing

Implementation (continued)
Go look at other plants for examples
Different product with same process Similar application Host of error proofing idea books

Manufacturing Systems Error Proofing

Lean Error Proofing

Lean error proofing is the lowest cost technique to prevent defects from occurring in the process.
Correctly Mounted

Pin Prevents incorrect Mounting Pin Added

Jig

Manufacturing Systems Error Proofing

Lean
New Processes
Start with simple device, probably with extra labor Make provisions for error proofing stations, but avoid initial expense

Existing Processes
If process is not stable, then use simple, flexible technique

Continuous Improvement
Simple lean devices are easier to improve than complex devices for expensive stations

Manufacturing Systems Error Proofing

Lean
Cost
Manual vs. Automatic

Consider:

Automatic Investment and higher burden rates

Maintenance
Spare part inventory Downtime

Manual

Cost of labor
Can wait time be utilized

Manufacturing Systems Error Proofing

Lean Error Proofing

The best chance for getting lean error proofing is to be very disciplined about generating numerous alternatives to evaluategetting ideas from everyone involved. The secret to having good ideas is to have a lot of them. Thomas Edison

Manufacturing Systems Error Proofing

No Change

Visual Control Colors Labels

Error Proof Detect: Stop the Line

Error Proof Prevent

Mechanical Electrical Devices

Product Process Design Change

Robustness Minimizing the failure of operator sensitive processes: Robustness Scale

Manufacturing Systems Error Proofing

Robustness Scale
Relating these examples to the robust scale on the previous slide, a bolt tightening operation would run the scale in the following manner:
Visual charts depicting that the bolt should be tightened to a specified torque and checked every so often. Bright paint on the wrench (and therefore on the bolt) to verify to the operator and others that the bolt has been tightened. Green and red light on torque gun to tell the operator weather or not the specified torque has been reached -- an alarm is sounded if the proper torque is not met.

Continue

Manufacturing Systems Error Proofing

Robustness Scale (continued)

Tying the feedback from the torque gun into the conveyance system to prevent the product from leaving the station until the specified torque has been reached. Same as above, but provide for removal and disposal of defect from process steam. Product designed so critically that torqued fastener is not required.

Manufacturing Systems Error Proofing

Robustness
Consider frequency, severity, and detection ability Make solutions as lean as possible Robustness not proportional to investment Some very inexpensive devices can 100% eliminate the potential for a mistake Getting team input will help ensure simple solutions as alternatives

Engineers tend to generate complicated solutions Continue

Manufacturing Systems Error Proofing

Robustness (continued)
NUMMI uses the whole spectrum of the robustness scale. Critical Concept -- Generate Numerous Alternatives to Evaluate.

Manufacturing Systems Error Proofing

Error Proofing Solutions Should Consider:

Maximum reduction of waste (scrap, rework, downtime, etc.)

Cost of method
Ease and timing of implementation Severity and frequency of the problem Root cause of the problem Extent of operator vigilance Preferences of operators Method reliability and maintainability

Manufacturing Systems Error Proofing

Visual Control Examples

Worker
Part Identification Start/Stop Points Andon Board Traffic Light Status

Material
Kanban Pull Signals Color Coded Containers Color Coded Racks

Contrast Identification
Model Specific Asymmetrical Geometry Workplace Organization Color Coded Components

Equipment
Color Coded Dies/Jigs Color Coded Fixtures PM Scheduling Board

Manufacturing Systems Error Proofing

Priority Setting

Customer Complaints or Contacts Should Get Immediate Attention and Error Proofing Should Always Be Considered As an Aid to Achieving Irreversible Corrective Action.

Manufacturing Systems Error Proofing

Managing and Documenting Issues

Error Proofing Project Reports and Summaries Error Proofing Control Plan Review Meetings Error Proofing Operator Instructions

Audit of Error Proofing Systems

Manufacturing Systems Error Proofing

Error Proofing Practices and Procedures

Continuous Improvement Teams need to be organized and properly staffed with the right people. People from different disciplines associated with the operation will generate a variety of solutions, and the best error proofing is achieved when there are several alternatives to select from for implementation.

Quality feedback systems are required to provide up to date information on defects. Key drivers of Error Proofing Projects should be RRPM, IPTV, FTQ, KPC, and KCC. Error Proofing should protect the customer from defects. Continue

Manufacturing Systems Error Proofing

Practices and Procedures (continued)

Projects need to be determined, goals established with responsibilities and timing determined. A priority setting system based upon the FMEA should be adopted. This system considers: 1. the likeliness for occurrence 2. the potential severity of a problem 3. the ability to detect the error

Continue

Manufacturing Systems Error Proofing

Practices and Procedures (continued)

Use of this system can help a plant sort out and focus on the most important problems to be resolved from a customers perspective. Project controls and follow-up are required to make certain the plan is being followed.

Need systems and organization to design out problems on new designs / processes (DFMEA & PFMEA).

Continue

Manufacturing Systems Error Proofing

Practices and Procedures (continued)

Root cause analysis and problem solving team dynamics are central to error proofing success. Make sure teams have trained members with the basic tools. If process is still unstable, tend toward simple, cheaper fixes with ongoing inspection until the operation stabilizes. Dont get paralysis by analysis. Quickly implement your best cost justified fixes.

Continue

Manufacturing Systems Error Proofing

Practices and Procedures (continued)

If automatic devices are considered a solution, select systems that have the simplest possible design, the lowest possible cost, and the lowest possible need for maintenance. Justify all changes. A team of people should evaluate changes to consider all alternatives, then select the best option. There are no automatic best approaches as evidenced by the vast array of methods employed at NUMMI.

Use 100% inspection in machine design but through error proofing devices built into the machine. Continue

Manufacturing Systems Error Proofing

Practices and Procedures (continued)

Focus on why not who. Consider benefits of visual controls like color coding. Develop supplier and vendor base. Develop audits to ensure error proofing devices are reliable long term. Some audits could become part of planned maintenance. Develop a tour program to share knowledge about good error proofing applications. Start over. Error proofing is a continuous process.

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

What is it?

A Formal Process to Ensure That Necessary Error Proofing Devices Are Implemented and Maintained in Your Plants.

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

How do I Institutionalize it?

A New Procedure or Local Operating Instruction (QS-9000) Should Be Written to Document Your 4-Step Error Proofing Verification Process.

Page: 1 of 2 Tracking Number:

Operating Instructions
Delphi Subject Title: Documentation Requirements For Error Proofing Methods

Originator: Bart Minogue

Approval Signature: Purpose:

Issue Date:

Revision Date:

Approval Date:

To describe how error proofing controls are developed, implemented, and audited including documentation requirements.

Instructions:
The PFMEA is intended to be utilized during the manufacturing planning stages for a new or changed product to identify potential failure modes of a process. Error proofing methods should be utilized to help eliminate process failures from occurring. PFME As should reflect both proactive and reactive error proofing solutions. Error proofing methods currently used in production which are planned for the process under consideration should be listed as a current process control on the PFMEA worksheet. The cross functional team responsible for the development of the PFMEA will list needed error proofing methods beyond current process controls as a recommended action, and assign a person responsible and a target completion date. Error proofing methods should be listed as a process function on the Process Flow Diagram, when applicable. The error proofing project is to be reflected in the Set-Up Sheets where applicable (e.g. in the process flow diagram, tooling or gage/master information). Error Proofing control methods, including audit requirements and a reaction plan should be listed in the Control Plan where applicable. The specific instructions necessary for the operator to properly operate/verify the Error Proof will be incorporated in the employee job instruction ( Job Instruction Guides, People Focused Practices, Visuals, etc.).
Rev 28-Jan-00

142

Page: 2 of 2 Tracking Number:

Operating Instructions
Delphi Subject Title: Documentation Requirements For Error Proofing Methods Originator: Bart Minogue Approval Signature: Potential Failure Modes Are Identified By A Cross-Functional Team (PFMEA Meeting) Current Error Proofing Methods In Production Are Listed As Current Process Controls Issue Date: Revision Date:

Approval Date:

PFMEA
List Current Methods As Current Process Control List New Methods As Recommended Action Process Flow Diagram List Error Proofing Method As A Process Function

Process Control Plan Audit Requirements Reaction Plan (For All KPC Processes)

Set-Up Sheets List Process Specs, Machines, and Error Proofing Panels (MS, SD#)

Employee Instructions Verification Procedure Audit Requirements

Rev 28-Jan-00 143

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

What are the Steps I Need to Follow? Step 1
Create & Maintain a Master List of Error Proofing Devices

Step 2
Create & Post Verification Instruction Sheets at Each Error Proofing Device

Step 3
Post & Use Log Sheets at Every Error Proofing Device to Ensure the Device is Working Properly

Step 4
Conduct Regular Compliance Audits of Each Error Proofing Device

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

Step 1: Master List of Error Proofing Devices A composite, master list of error proofing devices should be created and retained in your QS-9000 document center Each error proof should have a unique number New error proofing devices should be added to the master error proofing device list as they are identified

Manufacturing Systems Error Proofing

Plant Error Proofing Log

Tracking Number Prefix (error Department Department proof) Sequence EP-001 EPEPEPEPEPEPEPEPEPEPEPEPEPEPEPEPEPpage of

Description

Date

Owner

EP_TRK.XLS T. Meisel

printed 2/26/96 10:13 AM

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

Step 2: Verification Instruction Sheets Every error proofing device should have a corresponding verification instruction sheet that describes how the error proofing device works and how to verify that the device is working properly A master book of all verification instruction sheets should be maintained in your QS-9000 document center Verification instruction sheets should be posted at the error proofing device Verification instruction sheet retention period should be defined in your procedures

Page: 1 of 2 Tracking Number: ENG-014

Operating Instructions
Delphi Subject Title: Error Proofing Verification Instructions Originator: Bart Minogue Approval Signature: Abe Lincoln Purpose:
To describe the use of error proofing verification instruction within Plant 6.

Issue Date: 15MR96 Revision Date: 14MY96 Approval Date: 5/14/96

Instructions:
Error proofing verification instructions are generally required for error proofing devices that could accept non-conforming product when out of adjustment. Error proofing verification instructions shall be written in the format shown on page 2, and issued by the manufacturing engineer responsible for the error proofing device. The following shall be included in the instruction as appropriate: General description of error proofing device Step by step instructions explaining how to verify the error proofing device Frequency of verification checks Tool number or part number of items needed to use as part of the verification process

Error proofing verification instructions are assigned a tracking number by the manufacturing engineering documentation center representative. The master copy is to be stored in the manufacturing engineering documentation center and at the department(s) where used.
Obsolete error proofing verification instructions should be stamped Obsolete and forwarded to the manufacturing engineering documentation center representative. Rev 28-Jan-00
148

Page: 2 of 2 Tracking Number: ENG-014

Operating Instructions
Delphi Subject Title: Error Proofing Verification Instructions Originator: Bart Minogue Approval Signature: Abe Lincoln Issue Date:15MR96 Revision Date: 14MY96 Approval Date: 5/14/96
Page 1 of

Tracking Number:

Error Proofing Verification Instructions

Delphi Plant 6
Subject Title: Originator: Approval Signature: Issue Date: Revision Date: Approval Date:

This Form Is Available On The S: Drive On Coe S:\QS_9000\FORMS\E_PROOF.DOC

Rev 28-Jan-00

149

Manufacturing Systems Error Proofing

Tracking Number:

Error Proofing Verification Instructions

Delphi

E Proofing Description:

Originator:
Originator Signature:

Issue Date:

Revision Date:

Tracking Number:

Error Proofing Verification Instructions

Delphi E Proofing Description: Department 84 Rack and Pinion Assembly E. Proofing Originator: Doug Peter Issue Date: 01AP96 Revision Date: 10/10/96 7:02 PM

Originator Signature: Thomas Jefferson

Notify Advisor or Coordinator Immediately if Any Portion of Test Fails Verification of Error Proofing to be Performed Once Per Shift ER-84-1: Check Valve Station: SD-108703 Error Proof (A): Prevent upside down check valve from being assembled into gear. Method: The station automatically vacuum tests the check valve orientation in press head prior to press inserting check valve into the housing. Verification: Verify function by putting machine in auto and placing a check valve upside down in the press head. If the check valve present light on the panel does not come on, then the verification passes. Error Proof (B): Prevent two check valves from being assembled into the gear. Method: The station automatically pressure tests the vave housing for check valve presence by porting air through the inside of the valve bore to the pressure port. If pressure is high, then a check valve is present and the station will not press a check valve and will indicate a fault. Verification: Verify function by putting machine in auto and placing a housing that already has a check valve pressed into the pressure port. Auto cycle station, station should indicate reject. If yes, then the verification passes. Error Proof (C): Prevent missing label or wrong label. Method: The station automatically checks for the correct label. If the label does not match what the station is selected to run, then it will indicate a fault. Verification: Verify function by putting machine in auto and placing a housing that has a label different than the station is set to run. Auto cycle station, station should indicate reject. If yes, then verification passes.
Rev 28-Jan-00 151

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

Step 3: Error Proofing Device Log Sheets A log sheet should be posted at every error proofing device The log sheet is filled out by the operator each shift (or as specified) to document that the error proofing device is working properly Log sheet retention periods should be defined in your procedures

Manufacturing Systems Error Proofing

Tracking Number: EP-

Error Proofing Log

Operation Description: Freq. of Checks
C-Shift Date Time Verifier Pass Fail A-Shift Time Verifier Pass Fail B-Shift Time Verifier Pass Fail Material Corrective Action if Necessary Disposition

Oper.#

page 1 of 1 2/26/96 2:06 PM

EP_LOG.XLS T. Meisel

Manufacturing Systems Error Proofing

4-Step Error Proofing Verification Process

Step 4: Compliance Audits Regular compliance audits should be conducted by your quality assurance department to ensure the error proofing log sheets are being maintained in accordance with your procedures

Compliance audits can be conducted either daily, weekly, or monthly in accordance with your procedures Compliance audit form retention periods should be defined in your procedures

Date: 8-06-96 Inspection:

Error Proof Audit

Copies to: R. Erway, Mfg. Supt. Dept. Advisor, Quality Eng.

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155

Plant Error Proofing Best Practices Implementation Status Worksheet

Delphi Revised: 12MY97 Plant Error Proofing "Best Practices" Implementation Status

No.

Plant Error Proofing "Best Practices"

2 3 4 5 6 7 21 23 46 Kais Cadiz Livorno a 3 3 3 p a 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Southhampton 3 3 3

1 Plant Specific 1-Page Error Proof Initiative Report Exists & is Updated Monthly 2 Plant Chats RRPPM, IPTV, & $ Saved Improvements Monthly 3 Plant Tracks Number of Error Proofing Devices Implemented Each Month 4 Error Proof Operating Instruction Located in (General) in Document Center (Utilize PFMEA's to Document Error Proofs to be Implemented) 5 List of all Plant Error Proof Devices Exists and is Located in Document Center 6 Every Error Proof Device Has an Assigned Tracking Number 7 Error Proof Verification Sheets Exist for all Error Proof Devices 8 Master Book of all Error Proof Verification Sheets is in Document Center

3
3 p p a a a

3 3 3
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 p p

3
3 3 3

3
3 3 3 3 3 3

p 3 3 3 3 p p

3
3 3 3 3 3 3

9 Verification Sheets Posted at Every Error Proof Device

10 Error Proof Log Sheets in Place at all Error Proof Devices

p p p
p p

p
p p

11 Quality Assurance Conducts Regular Compliance Audits of all Error Proof Devices3 12 Ensure all Repairs go Through Designated Production Error Proof Processes

a =Active p =Partial Complete 3 =Complete

Rev 28-Jan-00

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Manufacturing Systems Error Proofing

4-Step Plant Error Proofing Verification Process 05MY97

Implementation Status
Plant / Location Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7 Plant 21 Plant 23 Cadiz Southhampton Strasbourg Kaiserslautern Livorno Mexico (ACE) Bangalore Works, India DHB / Trinter DAC Lingyun Dongfeng Xiaoshan Shanghai Export Contact George Washington Frazier Crane Jerry Seinfeld Ray Ramano Charlie Sheen George Jefferson Bob Newhart Greg Norman Arnold Palmer Harry Connick Tom Cruise Michael J. Fox Paul McCartney Ali Babba John Daley Mel Gibson Abe Lincoln Kevin Cosner Michael Douglas Robin Williams Tiger Woods Verification Master List Instructions 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Compliance Log Sheet Audit by Q.A. 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 15MY97 01JN97 01JN97 3

Manufacturing Systems Error Proofing

Remember
Error Proofing is not the responsibility of a single individual, but must be accomplished using the teamwork of cross-functional groups.

Manufacturing Systems Error Proofing

References
Source Inspection and the Poka-yoke System
Written by Shigeo Shingo Translated by Andrew P. Dillon

Improving Product Quality by Preventing Defects

Edited by Nikkan Kogyo Shimbun, Ltd. / Factory Magazine