Management
Lean Six Sigma Operational - Delegate Workbook
Mistake Proofing Techniques
2
Learning Objectives
At the end of this section delegates will be able to:
• Explain the role of Mistake Proofing within Lean Six Sigma
• Recognise that defects can be eliminated (100% of the time) • Understand that Mistake Proofing should be focused on process steps that rely on operator vigilance and concentration • Recognise that simple, low cost devices can be the most effective solutions
• Use a simple process for implementing a Mistake Proofing system SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
SSG06101ENUK - MP/Issue 1.1/ September 2008
1
©The British Standards Institution 2008
Lean Six Sigma Operational - Delegate Workbook
3
History of Error Proofing
• Dr Shigeo Shingo attributed with developing the methods
• Originally called Idiot Proofing but recognised that this label could offend workers so changed to Mistake Proofing (Poka
Yoke in Japanese)
• Literally translated
• Yokeru: to avoid
• Poka: inadvertent errors
• Target of Zero Defects and elimination of QC Inspection
SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
4
Human Error
• Humans make mistakes (errors) because of……
- Forgetfulness
- Misunderstanding
- Lack of experience/skills
- Lack of concentration
- Laziness
- Lack of standards
- Rushing
- Taking short cuts
- Malicious intent (deliberate action)
• Errors (can) lead to defects
• Defects are not inevitable and can be eliminated by the use of simple, low cost methods – zero defects
• Mistake Proofing should take over repetitive tasks that depend on vigilance or memory
SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
SSG06101ENUK - MP/Issue 1.1/ September 2008
2
©The British Standards Institution 2008
Lean Six Sigma Operational - Delegate Workbook
5
Types of Error
Four main types of error:
Processing
1.
Omitted Processing -
Mistake Proofing Techniques
2
Learning Objectives
At the end of this section delegates will be able to:
• Explain the role of Mistake Proofing within Lean Six Sigma
• Recognise that defects can be eliminated (100% of the time) • Understand that Mistake Proofing should be focused on process steps that rely on operator vigilance and concentration • Recognise that simple, low cost devices can be the most effective solutions
• Use a simple process for implementing a Mistake Proofing system SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
SSG06101ENUK - MP/Issue 1.1/ September 2008
1
©The British Standards Institution 2008
Lean Six Sigma Operational - Delegate Workbook
3
History of Error Proofing
• Dr Shigeo Shingo attributed with developing the methods
• Originally called Idiot Proofing but recognised that this label could offend workers so changed to Mistake Proofing (Poka
Yoke in Japanese)
• Literally translated
• Yokeru: to avoid
• Poka: inadvertent errors
• Target of Zero Defects and elimination of QC Inspection
SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
4
Human Error
• Humans make mistakes (errors) because of……
- Forgetfulness
- Misunderstanding
- Lack of experience/skills
- Lack of concentration
- Laziness
- Lack of standards
- Rushing
- Taking short cuts
- Malicious intent (deliberate action)
• Errors (can) lead to defects
• Defects are not inevitable and can be eliminated by the use of simple, low cost methods – zero defects
• Mistake Proofing should take over repetitive tasks that depend on vigilance or memory
SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008
SSG06101ENUK - MP/Issue 1.1/ September 2008
2
©The British Standards Institution 2008
Lean Six Sigma Operational - Delegate Workbook
5
Types of Error
Four main types of error:
Processing
1.
Omitted Processing -