DOCUMENTED

BHARGAVE INFORMATIONS
RUBBER Doc. No : QSP-37
PRIVATE LIMITED Revision : 00
Error Proofing Date : 16.08.2021

1. SUMMARY :

Mistake Proofing or Poka-Yoke methodologies can detect errors and prevent the non-
conforming part from moving to the next process. Furthermore, by implementing Error
Proofing techniques to detect the error at the source, we can prevent the non-conforming part
or product from being produced. Then we are truly on the road towards zero defects.

2. PROCEDURE :

 Review each step, thinking about where and when human errors are likely to occur.
 For each potential error, work back through the process to find its source.
 For each error, think of potential ways to make it impossible for the error to occur.
Consider:

 Elimination: eliminating the step that causes the error.

 Replacement: replacing the step with an error-proof one.
 Facilitation: making the correct action far easier than the error.

 If you cannot make it impossible for the error to occur, think of ways to detect the
error and minimize its effects. Consider inspection methods, setting functions, and
regulatory functions expanded on below.
 Choose the best mistake-proofing method or device for each error. Test it, then
implement it. Three kinds of inspection methods provide rapid feedback:

 Successive inspection is done at the next step of the process by the next
worker.
 Self-inspection means workers check their own work immediately after doing
it.

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 DOCUMENTED
BHARGAVE INFORMATIONS
RUBBER Doc. No : QSP-37
PRIVATE LIMITED Revision : 00
Error Proofing Date : 16.08.2021

 Source inspection checks, before the process step takes place, that conditions
are correct. Often it’s automatic and keeps the process from proceeding until
conditions are right.

Error-proofing is the activity of awareness, detection, and prevention of errors that could
adversely affect our customers (defects) and our people (injuries), and result in 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.
There are two main techniques for error-proofing:

 “Poka-Yoke” System – Devices or inspection techniques are put in place that assure that setup
is done correctly; i.e., 100% good parts are produced from the first piece onward.
Regardless of the technique you decide to apply (and you will probably decide to apply them
both), the error -proofing process has some common steps that ensure success:

 Identify – The organization needs to identify error-proofing opportunities through

PFMEA, quality data, PR/R, warranty data, brainstorming (questions to ask, freeform …),
etc.
 Analyze – The organization needs to prioritize the error-proofing opportunities,
determine the level of error-proofing required, brainstorm, and select the error-proofing
mechanisms.
 Plan – The organization needs to determine process mechanisms for error-proofing,
define actions plans, and create the Error-Proofing Control Plan.

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 DOCUMENTED
BHARGAVE INFORMATIONS
RUBBER Doc. No : QSP-37
PRIVATE LIMITED Revision : 00
Error Proofing Date : 16.08.2021

 Implement – The organization needs to implement various activities to put the error-
proofing process into practice, such as installation, validation, check sheet/log, and
operator instructions.
 Evaluate – Finally, the organization needs to evaluate the effects of the actions taken, and
if the number of errors has not decreased as expected, an additional set of actions should
be taken.

The error-proofing process can help you ensure consistency during setups, prevent the production
of defective parts, make quality problems more visible, eliminate waste due to inspection and
repair, and lower the costs of design and manufacturing.

3. RECORDS :

S.No Record name Record number Retention period

Immersion Time Monitoring Record
1 FR/STM/01 Permanent until superseded
(Shell Treatment Process )
Curing Time Monitoring Record
2 FR/CTM/01 Permanent until superseded
( SCADA )

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