EIN 6935 /4933 LEAN Six Sigma

6.2 MISTAKE PROOFING

Instructor: Christos Nicolaou

Learning Objectives

What is Mistake-Proofing (or Poka-Yoke)

Reasons for Human Error

Mistake-Proofing Methods

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To err is human

Mistake or Error is something done incorrectly. Defect is when an error or mistake is not prevented or detected and it escapes to next operation, or worse by far, to our end customer. The question is: How can we prevent errors and mistakes or stop them from becoming defects?

Reasons for Human Error Lack of knowledge, skills, or ability Mental errors Sensory overload Mechanical process errors Distractions Loss of memory Loss of emotional control

DEFECTS are the result of ERRORS ERRORS are the cause of DEFECTS
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Mistake-Proofing (or Poka-Yoke)

Using ingenuity to create devices that allow us to do our job 100% error free 100% of the time. Make them simple Make them inexpensive Design for prompt feedback Design for preventive action Focus on the application Input from right people Even in the best systems there are chances for errors or mistakes.

A Simple Idea Can Be a Great Way to Mistake-Proof a Problem

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Mistake Proofing Works Well Where:

Worker vigilance is needed (manual operations) Mis-positioning can occur. Adjustment is required. SPC is difficult to apply or ineffective. Attributes, not measurements, are important. Training cost and employee turnover are high. Mixed model production occurs. Users make mistakes and blame the service provider. Special causes reoccur. Field failures are extremely expensive.

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Everyday Examples of Mistake-Proofing

The Sneak a Cup feature on coffee brewers. Beeper on ATMs so that we wont forget card. We cant shift from park unless brake pedal is depressed. Kill switch on treadmills. Picture on bill changer to insert bill correctly. KittingSeven day medicine/pill dispensers Lock-out fields and tab control on electronic forms

We Often Take It for Granted, but Mistake-Proofing Is All Around Us

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Mistake-Proofing Methods

ELIMINATION REPLACEMENT PREVENTION FACILITATION DETECTION MITIGATION

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Mistake-Proofing Methods

ELIMINATION seeks to eliminate the possibility of error by redesigning the product or process so that the task or part is no longer necessary. Product simplification or part consolidation that
avoids a part defect or assembly error in the first place. Eliminate decisions and steps.

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Mistake-Proofing Methods - ELIMINATION

Air baffles needed to be

attached to cover to direct airflow over hot components.

Alternative design has baffle

function stamped into sheet metal cover eliminating troublesome assembly step.

Adhesive could come loose if

not properly applied.

Baffle also prone to damage

during assembly.

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Mistake-Proofing Methods

REPLACEMENT substitutes a more reliable process to improve consistency. Automatic dispensers or applicators to insure the
correct amount of a material such as an adhesive is applied.

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Mistake-Proofing Methods - REPLACEMENT

Alignment of the adhesive

overlay on the faceplate was critical over a series of port holes.

The new model replaced this

process by eliminating the adhesive overlay and using a more reliable silk screen process.

If mis-aligned, the overlay

would need to be stripped off, the surface cleaned, and a new overlay applied.

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Mistake-Proofing Methods
PREVENTION engineers the product or process so that it is impossible to make a mistake at all.
Part features that only allow assembly the correct way Unique connectors to avoid misconnecting wire harnesses or cables Part symmetry that avoids incorrect insertion

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Mistake-Proofing Methods - PREVENTION

Two-door and four-door models are
produced on this line.

The fixture is built so that it is

impossible to put a four-door part in place when the fixture is set-up for a two-door model and vice-versa.

Notice the limit switch in centerright which helps insure proper orientation.

If correct part is turned backward or

upside down, it will not fit.

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Mistake-Proofing Methods
FACILITATION employs techniques and combining steps to make work easier to perform. Visual controls including color coding, marking or
labeling parts to facilitate correct assembly A staging tray that provides a visual control that all parts were assembled, locating features on parts

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Mistake-Proofing Methods - FACILITATION

Board orientation on
bottom row 180 different from top row.

Color coded board

insertion screws and panel color-coding facilitate correct board orientation for insertion.

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Mistake-Proofing Methods

DETECTION involves identifying an error before further processing occurs so that the user can quickly correct the problem. Sensors in the production process to identify when
parts are incorrectly assembled, built-in self-test capabilities in products.

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Mistake-Proofing Methods - DETECTION

A conveyor carries the
product under a pivoting flag.

A correctly assembled
product passes under the flag.

An incorrectly assembled
product tips the flag, and a sensor detects the flag movement.

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Mistake-Proofing Methods

MITIGATION seeks to minimize the effects of errors. Fuses to prevent overloading circuits resulting from
shorts Products designed with low-cost, simple rework procedures when an error is discovered Extra design margin or redundancy in products to compensate for the effects of errors

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Mistake-Proofing Methods - MITIGATION

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Mistake-Proofing
Ideally, mistakeproofing should be considered during the development of a new product to maximize opportunities to mistake-proof through design of the product and the process.
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Mistake-Proofing Attitude

If it can be done wrong, it will be! Mistakes can be eliminated! One mistake out the door is one too many!

Mistake-Proofing Can Help Us Become More Competitive!

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Poka Yoke: Mistake Proofing ~ 2:26 mins

http://www.youtube.com/watch?v=2RthkxGwFsU&fea ture=player_detailpage

Class Participation

Name some mistake proofing methods and/or devices

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