Mistake-proofing Philosophy
Error Prevention is better than Defect Detection
➢ Errors are the Cause
➢ Defects are the Result
➢ Defects are Prevented If:
➢ Errors are prevented from happening
➢ Errors are discovered and corrected 9
Mistake-proofing Philosophy
➢ Mistake-proofing philosophy recognizes that people sometimes
forget and make errors.
➢ The approach uses common-sense ideas and methods in both
process and product to eliminate human and mechanical errors.
➢ Historically, these concepts greatly applied to Safety and accident
prevention
➢ Same approach must drive intolerance for scrap & rework.
Fact: People Make Mistakes.
A good Poka-Yoke device makes it impossible to make a mistake.
Variation Causes Defects
Common Special
cause Cause
All repetitive activities have
Variation ( fluctuation ) - A fact of life
Sources of Variation - 5M + 1 P
Variation Causes Defects
Human Mistakes: Simple errors are the most common cause of
defects-occur unpredictably.
❖Goal of Zero Defect Quality (ZDQ) is ZERO!
Make certain that the required 3M conditions
are in place and maintained to make
acceptable product 100% of the time
1. Machine
2. Method/ Process
3. Material. 4
Attributes of Zero Defect quality system
•Source Inspection - Checks conditions at the source
•100% Inspection - Simple Poka-Yoke devices in place to check every time the process occurs
•Immediate Action
➢Operations stop and corrective action is taken when a defect occurs.
➢Teams brainstorm and implement new devices wherever there is an
opportunity for error
Quality can only be assured when there is always immediate feedback at the source of
the defect.
Corporate Training Modules
Geometric Dimensioning & Tolerances Sheet Metal Part Maunufacturing
Fundamentals of GDNT Creating Value ( Yield Improvement) in Stamping Process
Blue Prints/ Drawings reading and Understanding Dies Design best practice for very high tensile steel
Limit, Fits & Tolerances Die Maintenance Technique
GDNT Advance New Die Development Process
Productivity Improvement in Stamping Process
Total Productive Maintenance (TPM) Lean Thinking & Lean Management
TPM Champion Lean Champion
7 Steps of Autonomous Maintenance (Jishu Hozen) Lean Quick Changeover (SMED)
Initial Phase Development Management Way of Toyota - Lean manufacturing System
Focused Improvement - 16 Losses & OEE improvement Toyota A3 Tool (Toyota Business Practice)
How to Calculate OEE ? How to improve OEE, Productivity
Basics of Manufacturing Excellence Value added Quality Management Systems
Applied 5S PPAP & APQP
Kaizen for maufacturing SPC ( Statistical Process Control
Seven QC Tools : Deep anlysis and problem solving Zero Defect Quality Through Jidoka, Poka Yoke
Seven Steps of Problem Solving CAPA - Problem Solving Technique
Root Cause & 5 Why Analysis Total Quality Management (TQM)
Visual Management, 3 M Waste Elimination Global 8D - rapid problem solving Technique
VA/ VE for cost reduction Toyota A3 Tool - Proactive Problem Solving Technique
Ashish Aggarwal Corporate Trainer & Consultant Mob no : 9643002507. 9873191528
Gmail :
[email protected]
