Mistake-proofing

From HMCwiki

Mistake-proofing is the foundation of Poka-Yoke; a concept introduced in Japan by Shigeo Shingo.

When mistake-proofing, an organization can choose to view errors as inevitable or as preventable occurrences that can be eliminated. The mindset that is chosen determine the results that will follow. Would you rather be a worker who is in a company that continually drives out error or a worker who is looking for someone to blame? Which company will keep it’s customer happy? You had better detect quality errors before your customer does or you will not be in business long.

Also, an error-less output cannot be achieved through assuming or sampling. It is achieved where key attributes of the product or services is inspected as it moves through the system. The user is the best inspector.

Remember, don’t make what you don’t need. Move to the just-in time principle. The less you have to manage, the less chance of something going wrong.

Reasons for errors

• Forgetfulness
• Misunderstanding
• Identification
• Amateurs
• Intentional errors
• Inadvertent (non thinking) errors
• Slowness
• No Standards
• Surprises

What mistake proofing eliminates

The Five Best Poka-yokes

• Guides and pins
• Error detection and Alarms
• Limit Switches
• Counters
• Checklists

Basic Functions of Poka-yoke

• Shutdown
• Control
• Warning

If you make it easier to do it right than to do it wrong, your change will last over time.

To seek out the true cause: ask Why five times, then how do we fix it.

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