Error Proofing
We have extensive experience in implementing poka-yoke systems in manufacturing environments. Our team will work with your organization to identify the processes or product features that require improvement, then design and implement appropriate solutions.
As shown in the Different Levels of Mistake Proofing chart below, we strive for all solutions to be in the right-hand Error Proofing: Cannot Make category. Our Ujigami™ plant floor collaboration software is designed to link together the Technical and Behavioral Solutions.
The Different Levels of Mistake Proofing
Behavioral Solutions |
Technical Solutions | |||
| QS Procedures | Mistake Proofing: Cannot Accept |
Mistake Proofing: Cannot Pass |
Error Proofing: Cannot Make | |
|
Inspection and Testing Control of Non-Conforming Product |
Defect has been produced upstream.
The process looks for known defects with parts entering the process. |
A processing error has occurred.
The process is stopped before the defect is produced or holds onto the defect if one has been produced. |
Error cannot occur.
The possibility of error has been designed out of the product or process. | |
| More desirable than poor quality products at the customer. | Method of Prevention | |||
| Detection entering or leaving the process | Process detection | Design | ||
|
Least Desirable |
|
Most Desirable | ||
| Behavioral solutions depend upon management follow-up, employee discipline, work instructions, and training. | Level 3:
Cannot Accept or Pass |
Level 2:
Cannot Cycle |
Level 1:
Cannot Make | |
|
Detection Method | |||
| Identify Suspect Defect | Identify Suspect Action | Identify Suspect Part or Process | ||
| Corrective Action | ||||
| Eliminate Part Redesign Part Change Process |
Action Sensing (stop the action) |
Defect Sensing (detect the defect) | ||
Please note: We error proof all of our error proofing solutions, so you don't get any surprises on your shop floor.
Last Updated: 19 May 2004 3:40:31am