Error Proofing Training

A Strategy to achieve
Performance Excellence

C. Padmanabhan
January,2009
 Definition of Error Proofing

Error Proofing is a process of

Anticipating, detecting, and preventing errors and defects that

adversely affect customers.

Utilizing techniques that prevent errors.

Poka-yoke: (From the Japanese, yokeru – to prevent, and poka –

inadvertent errors.) Simple, inexpensive, failsafe devices or systems
which prevent mistakes from being made or from becoming defects.

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 This is not about Punishing Workers

Mistake proofing recognizes that every human

will make mistakes and tries to set up systems
that minimize or eliminate those mistakes.

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Typical Illustration

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 Evidence of the Effectiveness

Devices Tend to be Inexpensive...

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0.9
0.8
0.7
Probability

0.6
Frequency of Occurrence
0.5
0.4 Cumulative Probability
0.3
0.2
0.1
0
$100 to$250

$250 to $1000
$25 to $100
$25 or less

$1000 or more

Cost
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 Why is “Zero Defects” an Important
Concept?

Maintain Customer Satisfaction & Loyalty

Happy Customers mean more sales!

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Why is “Zero Defects” an Important
Concept?

COST

There is always a cost

associated with
manufacturing defects!

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 Costs of Defects ?

Does it cost more to make processes better ?

No Making processes better leads to reduced

Rework
Scrap
Warranty costs
Inspection costs
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 1-10-100 Rule

The 1-10-100 rule states that as a product or service moves

through the production system, the cost of correcting An error
multiplies by 10.
Activity Cost
Order entered correctly $1
Error detected in billing $ 10
Error detected by customer $ 100
Dissatisfied customer shares the experience with others the
costs is
$1000
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 Mistake-Proof or Poka-yoke the process!

Recognize that it is
natural for people to make
mistakes.

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 Mistake-Proof or Poka-yoke the process!

Not noticing that an error

is made or a machine is
not functioning does not
make a person stupid or
foolish.

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 Sources of Errors

Methods

Materials

Design of Product/Process

Machine/Process

Human Error

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 Sources of Errors
Materials:
• Damaged Methods:
• Out-of-spec • Non-compliance
• Wrong parts • Poor job instructions

Design:
• Poor design
• Not robust
• Poor design Errors Defects
for Mfg. (DFM)

Machine/Process:
• Lack of Planned Human Error:
Maintenance/Production • Process problems
Maintenance Partnership • People Focused Practices
• Process abnormality not followed
• Workplace setup • Lack of training
• Improper adjustment • New to job
• Manufacturing difficulty • Inadvertent mistakes
• Incapable process 13
What do you Fail safe?

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 Error, Defect, and Source

What is the definition of an error?

Error: is the cause/reason for the defect
What is the definition of a defect?
Defect: is the result of an error 15
 Error, Defect, and Source

Loose door hinge bolts

Low Pressure

Loose door hinges

What is the defect?______________________________

Low air pressure

What is the error?______________________________ 16
 Error Proofing Components

Checking Methods
• Feature
• Count
• Motion-step

Inspection Methods
• Judgement Error Proofing
• Informative
– Successive Device
– Self
• Source

Correcting Methods
• Warning
• Control/Halt 17
 Checking Methods

Three Types of Checking Methods

Feature

Count
5th

4th step
Motion-step
3rd step

2nd step

1st step
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 Feature Checking Method

Definition: A method for checking the physical characteristics

of a part or process to differentiate it from a standard.

Types of Features
ERROR
PROOFING
Process PROCESS
Product

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 Process Features

What is a Process Feature?

Process Feature Examples:
• Air pressure
• Heat
• Time
• Anything that affects the process

How do we implement a Checking Method on a Process

Feature?

Checking Method examples:

• Air pressure gages
• Electronic gages
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• Sensors
 Product Features

What is a Product Feature?

No Go
Product Feature Examples:
• Size
• Inside diameters
• Thickness
• Color
How do we implement a Checking Method on a Product
Feature?

Checking Method examples:

• Sensors
• Electrical reading devices
NAME PLATE
• Locator pins
• Assembly jigs 21
 Checking Method

Count Checking Method

Definition: A method that incorporates counting the number of parts per

assembly or the number of tasks to complete an operation.

Torque Confirm

Cl

k
ic

ic
k

Cl
Count Checking Method Examples:
• Click wrenches
• Kitting (packaging parts of an assembly)
• Counting the number of bolts on an assembly
Hood bolt kit
• Light curtain in a parts bin 4 each
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 Checking Method

Motion-step Checking Method

Definition: a method in which defects are detected by checking for

errors in sequence of operations or elements. This applies to
operations that must be carried out with pre-determined motions or critical
sequence.

Motion-step Checking Method Examples: 5

2 3
• Lapped parts
• Fasteners needing to be 4 1
tightened in a particular sequence. 6
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 Inspection Methods

Three Types of Inspection Methods

Judgement
Informative

Successive

Self
Source
The first two approaches are widely used and
considered traditional.
Only Source Inspection actually eliminates defects.
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 Cycle for Managing Errors and Defects

(c)
Check

(b)
Feedback Basic Cycle Defect

(d)
Error

(a)
a) Error occurs in-station
b) Resultant defect is passed on
c) Defect is detected downstream
d) Feedback provided for process improvement
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 Inspection Methods

Judgement Inspection Method

What are some drawbacks?

Provides little or no feedback to the

operator.

Does not occur in-station

Incorporates end-of-line inspection

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 Judgement Inspection Method

• End-of-line inspection
Check
• May catch defects prior
to shipment
Feedback Defect
• Weak feedback to
upstream processes
Error

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 Inspection Methods

Informative Inspection Method

Definition: An inspection that feeds back the defect occurrence to the

work process; the process then takes action to correct the operation.

Two types of Informative Inspection Method

Successive inspections
Self-inspections

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 Inspection Methods

Successive Inspection Method

Definition: An inspection that is performed as close as possible

downstream of the operation; this method also provides a
feedback loop to the error or defect origin.

Downstream

Flow
Upstream 29
 Informative: Successive Inspection

Touch or use marker to

highlight completed operation Check

Follow process inspections

Inform the previous process of

Feedback Defect
defect

Defect reduction depends on

problem solving skills
Error

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 Informative: Self-Inspection

Definition: An inspection method that is done in-station and

provides immediate feedback.

• Inspect own work Check

• Receive immediate feedback

• Enable instant corrective action
• Improve ability to root cause Feedback Defect
problem
• Maximum number of errors or
defects?
Error

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 Inspection Methods

Source Inspection Method

Definition:

• An inspection that detects errors in-station that give rise to defects

• Prevents defects
• Performs feedback and action at the error stage to keep errors from
becoming defects.

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 Source Inspection Method

Detect error before

processing Check
Use error detection
device(s)

Feedback Defects

Provide feedback at the

error stage Error Action
Stop process before error
becomes a defect
Check Feedback

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 Correcting Methods

Warning Correcting Method

Informs the operator that an error or

defect has just occurred.
Uses audible alarms.

e.g., sirens, horns, bells
Uses visual alarms.

e.g., flashing lights, indicator
boards

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 Correcting Methods

Control/HaltACorrecting Method
Defects

Interlocks with the process

Halts the process

Requires operator interaction with the defect

Operator must correct or seek

support

Process is ready to continue after

the solution is implemented

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 3 Rules of POKA-YOKE

 Don’t wait for the perfect POKA-YOKE.

Do it now!
 If your POKA-YOKE idea has better
than 50% chance to succeed…Do it!
 Do it now….improve later!

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Next Steps!

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 Identify the Poke Yoke in the Process

Step1: Make a Poke Yoke Map for each process

and keep it in front of each Cell.

Step2: List the no. of poke yoke in each cell

Step3: Identify the poke yoke for each failure
mode
Step4: Make Action plans for implementation

The Maximum number of Poke Yoke made by Supplier will be

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awarded as Best Poke Yoke Supplier of the Year2009
 Template for Improvements

Process Improvements
MODEL AREA DATE

Supplier:

Before After

te
a
pl
e m
t
his
et
Photo Photo

us
s e
lea
P
PROBLEM: IMPROVEMENT

BENEFITS:

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