OPERATIONAL EXCELLENCE
C O N S U L T I N G
1 February 26, 2014 – v 4.0
Operational Excellence - Mistake-Proofing
Workshop ...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
4 February 26, 2014 – v 4.0
Getting 99.9% “right” may not be “good enough”
Gett...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
7 February 26, 2014 – v 4.0
Inputs can be classified as one of three types:
Con...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
10 February 26, 2014 – v 4.0
The Process Flowchart
Mistake-Proofing a process s...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
13 February 26, 2014 – v 4.0
A few more Tips:
Break the process into manageable...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
16 February 26, 2014 – v 4.0
“Mistake Proofing” Course Agenda
1. Introduction t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
19 February 26, 2014 – v 4.0
Workshop Exercise: Coffee Brewing Process
Instruct...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
22 February 26, 2014 – v 4.0
Failure Mode and Effects Analysis or FMEA is a
sys...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
25 February 26, 2014 – v 4.0
Benefit of a Process FMEA
The benefits of the Proc...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
28 February 26, 2014 – v 4.0
Process FMEA - The Template
PROCESS FMEA
Process N...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
31 February 26, 2014 – v 4.0
Process FMEA - Potential Failure Modes
Process Ste...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
34 February 26, 2014 – v 4.0
Root Cause Analysis (RCA) Tools
Thorough probing t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
37 February 26, 2014 – v 4.0
Root Cause Analysis Tools → Why – Why Diagram
Fail...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
40 February 26, 2014 – v 4.0
How to develop a Fishbone Diagram
Step 1: Define t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
43 February 26, 2014 – v 4.0
“Mistake Proofing” Course Agenda
1. Introduction t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
46 February 26, 2014 – v 4.0
Process FMEA - Example for Occurrence Ranking
Rank...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
49 February 26, 2014 – v 4.0
Risk Priority Number (RPN):
For higher RPN’s the t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
52 February 26, 2014 – v 4.0
Actions that will influence the Process FMEA risk ...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
55 February 26, 2014 – v 4.0
Human Errors are inevitable !!!
Errors can´t be av...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
58 February 26, 2014 – v 4.0
1. Work Progress
Understanding
Start
End
2. Work O...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
61 February 26, 2014 – v 4.0
1. Failures in “Understanding the Work Progress”
1...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
64 February 26, 2014 – v 4.0
4. Failure in “Recognizing Correct Motion to be Do...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
67 February 26, 2014 – v 4.0
1. Work Progress
Understanding
Error Modes (1) - (...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
70 February 26, 2014 – v 4.0
iii. Assembling the part onto the sub-assembly pro...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
73 February 26, 2014 – v 4.0
Variation Control
Use of special jigs, fixtures, o...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
76 February 26, 2014 – v 4.0
Requirements:
• The outcome of the process or rout...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
79 February 26, 2014 – v 4.0
1. Guide Pins
Guide pins of different sizes and/or...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
82 February 26, 2014 – v 4.0
3. Limit Switches
Limit switches are electro-mecha...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
85 February 26, 2014 – v 4.0
5. Vision Systems
Vision systems use cameras to lo...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
88 February 26, 2014 – v 4.0
Human Errors → Mistake-Proofing Examples
SIM cards...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
91 February 26, 2014 – v 4.0
Human Errors → Mistake-Proofing Examples
It only f...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
94 February 26, 2014 – v 4.0
Human Errors → Mistake-Proofing Examples
Well Desi...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
97 February 26, 2014 – v 4.0
“Mistake Proofing” Course Agenda
1. Introduction t...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
100 February 26, 2014 – v 4.0
Process: Name of the process to be controlled
Pro...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
103 February 26, 2014 – v 4.0
The OCAP is a systematic and ideal problem-solvin...
OPERATIONAL EXCELLENCE
C O N S U L T I N G
106 February 26, 2014 – v 4.0
“Mistake Proofing” Course Agenda
1. Introduction ...
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OpEx Mistake-Proofing Training Module

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This Slideshare presentation is a partial preview of the full business document. To view and download the full document, please go here:
http://flevy.com/browse/business-document/opex-mistake-proofing-training-module-600


The Operational Excellence Mistake-Proofing Training Module includes:

1. 106 PowerPoint slides covering Introduction to Mistake-Proofing, Process Mapping, Building Block, Process Failure Mode and Effects Analysis (Step-by-Step Instructions), Human Work Model, Sixteen Human Error Modes, Six Mistake-Proofing Principles, Five Mistake-Proofing Methods, Seven Types of Poka-Yoke Devices, Poka-Yoke Examples, Process Control Plan (Step-by-Step Instructions) and 6 Workshop Exercises.

2. MS Excel Process FMEA Template

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OpEx Mistake-Proofing Training Module

  1. 1. OPERATIONAL EXCELLENCE C O N S U L T I N G 1 February 26, 2014 – v 4.0 Operational Excellence - Mistake-Proofing Workshop Instructor: Frank Adler, Ph.D. Operational Excellence Consulting
  2. 2. OPERATIONAL EXCELLENCE C O N S U L T I N G 4 February 26, 2014 – v 4.0 Getting 99.9% “right” may not be “good enough” Getting it right 99.9% of the time means … 268,500 defective tires shipped per year. 22,000 checks deducted from the wrong account every hour. 19,000 babies dropped at birth per year. 12 babies given to wrong parents each day. 2 unsafe landings at O’Hare airport per day.This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  3. 3. OPERATIONAL EXCELLENCE C O N S U L T I N G 7 February 26, 2014 – v 4.0 Inputs can be classified as one of three types: Controllable (C) – can be adjusted or controlled during the process • speeds, pressure, ... Standard Operating Procedures (SOP) – common sense items; activities that are always done just because it makes sense • set-up, cleaning, maintenance, ... Noise (N) – things one cannot control – things one doesn't want to control (too difficult or expensive) • humidity, temperature, ... Mistake-Proofing - Characterize Process Inputs This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  4. 4. OPERATIONAL EXCELLENCE C O N S U L T I N G 10 February 26, 2014 – v 4.0 The Process Flowchart Mistake-Proofing a process should begin with a flow chart and a high-level risk assessment (based on available data) of each process step. A Process Flowchart is a graphical process description of the work flow or activities using standard symbols for each of the activities. Different types of activities are described with standard symbols. The problem areas in the process are often relatively easy to discover when assessing the flowchart. An ellipse shows the start and the end point of the process. A box describes an activity or process step. A diamond shows a decision making step. An arrow shows the direction from one activity to another. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  5. 5. OPERATIONAL EXCELLENCE C O N S U L T I N G 13 February 26, 2014 – v 4.0 A few more Tips: Break the process into manageable process steps But don’t worry too much, you can always continue doing that when starting to analyze the process step if needed Try to keep it to max. 10 - 15 process steps You can always split process steps later or split the process into several sub- processes and form a project team around each sub-process Verify that the process flow chart is accurate and complete Perform a process walkthrough and/or onsite process observation to ensure the you did not miss anything and all steps are in the correct sequence Make sure you have all the right people on board The process flow chart helps you to understand who is involved in the process. Pull subject matter experts in as and when needed The Process Flow Chart This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  6. 6. OPERATIONAL EXCELLENCE C O N S U L T I N G 16 February 26, 2014 – v 4.0 “Mistake Proofing” Course Agenda 1. Introduction to Mistake-Proofing (≈ 30 min) 2. Process Mapping & Exercise (≈ 35 min) 3. The Building Block & Exercise (≈ 35 min) 4. Process FMEA & Exercise (≈ 100 min) 5. Risk Analysis & Exercise (≈ 45 min) 6. Human Errors and Poka-Yoke & Exercise (≈ 60 min) 7. Process Control Plan & Exercise (≈ 60 min) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  7. 7. OPERATIONAL EXCELLENCE C O N S U L T I N G 19 February 26, 2014 – v 4.0 Workshop Exercise: Coffee Brewing Process Instructions to Exercise 2: Develop a Building Blocks Diagram for the Coffee Making Process. Draw a Building Block Diagram on a Flip Chart Define the “Product In” and “Product Out” of the process Brainstorm Building Block elements in no particular order, write them on Post-It notes and stick them on the Flip Chart under the appropriate category (Information In, Resources, Controls, …) Resources for Exercise 2: Flip Charts Post-It Notes Markers 20 Minutes This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  8. 8. OPERATIONAL EXCELLENCE C O N S U L T I N G 22 February 26, 2014 – v 4.0 Failure Mode and Effects Analysis or FMEA is a systematic methodology used to analyze the reliability of processes or products, i.e. latent process or product component failures and their effects on the overall process/product performance and/or safety. Failure Mode and Effects Analysis - Definition This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  9. 9. OPERATIONAL EXCELLENCE C O N S U L T I N G 25 February 26, 2014 – v 4.0 Benefit of a Process FMEA The benefits of the Process FMEA are: assists in the analysis of the manufacturing or business process, and identifies process deficiencies and offers a corrective action plan, identifies the critical and/or significant characteristics and helps in developing process control plans, establishes a priority of corrective actions, documents the rationale for changes. Process Failure Mode and Effect Analysis - Benefits This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  10. 10. OPERATIONAL EXCELLENCE C O N S U L T I N G 28 February 26, 2014 – v 4.0 Process FMEA - The Template PROCESS FMEA Process Name: FMEA Team: Ranking Guidelines: [attached as copy] FMEA Worksheet Document No: Process Responsible: Severity of failure effect: 1 = Minor/No effect 10 = Very high/Hazardous File Location: FMEA Responsible: Occurrence of failure cause: 1 = Remote/Unlikely 10 = Very high/Almost inevitable Date (Orig.): Other Areas Involved/Effected: Detection of failure cause: 1 = Very high/Almost certainly 10 = Very low/Unlikely Date (Rev.): Risk Priority Number (RPN) = Severity * Occurrence * Detection Page of Process Description and Potential Potential Severity Potential Occurrence Current Process Detection RPN Recommended Responsible Completion Status Action Results Process Purpose Failure Mode Effect(s) of Failure of effect Cause(s) of Failure of cause Control(s) of cause (S*O*D) Action(s) Person Date Action Taken [S] [O] [D] RPN The Process FMEA should be part of your Quality Management System. Manage it like you manage every other document. Every Process FMEA should have an owner. It is the owner’s responsibility to understand and consider if process changes will impact the performance of other processes The Process FMEA should be a living document. Make sure it is updated by the owner as needed and review it periodically as you review any other QMS document …This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  11. 11. OPERATIONAL EXCELLENCE C O N S U L T I N G 31 February 26, 2014 – v 4.0 Process FMEA - Potential Failure Modes Process Step Description: “Inserting the Coffee Filter” Process Step Success Criteria: Filter Present – Right Filter – Right Position – … Potential Failure Modes: No Filter – Too many Filters Filter too small – Filter too large – Wrong Type Filter misaligned – Filter not opened This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  12. 12. OPERATIONAL EXCELLENCE C O N S U L T I N G 34 February 26, 2014 – v 4.0 Root Cause Analysis (RCA) Tools Thorough probing to root causes will lead to broad, fundamental issues, involving management policies, product design, process capabilities or process control, technology constraints, standard operating procedures, work instruc- tions, training, … . Root Cause Analysis Tool Box: The 5 Why’s Why – Why Diagram Fishbone Diagram Is – Is Not Matrix Affinity Diagram Interrelationship Diagram Scatter Diagram Box Plots Histograms Process Capability Studies SPC or Pre-Control Charts … This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  13. 13. OPERATIONAL EXCELLENCE C O N S U L T I N G 37 February 26, 2014 – v 4.0 Root Cause Analysis Tools → Why – Why Diagram Failure Mode: Customer complaint due to grinding marks on the door frame The door frame had been “over- ground” Wrong Tool was used Operator was untrained Current grinding method is not capable Cosmetic requirements not understood Current grinding method is too complicated Description: The Why-Why Diagram helps to identify possible causes of a problem or failure mode in a graphical and systematic manner. The tools helps the team to recognize the broad network of possible causes and the relationship among them. Example: No written cosmetic standard exists No formal training exists Training Process was not applied Tools are not marked … … This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  14. 14. OPERATIONAL EXCELLENCE C O N S U L T I N G 40 February 26, 2014 – v 4.0 How to develop a Fishbone Diagram Step 1: Define the failure mode to be analyzed Step 2: Draw a horizontal trunk line (the backbone of the fish) and to the right end of this write the failure mode (= fish’s head) Step 3: Draw the main branches and write the selected categories at the end of each main branch Step 4: Brainstorm for all possible causes for each of the selected categories Step 5: Group the possible causes under each of the categories and draw a minor branch for each cause Step 6: Check that the diagram is complete and logical This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  15. 15. OPERATIONAL EXCELLENCE C O N S U L T I N G 43 February 26, 2014 – v 4.0 “Mistake Proofing” Course Agenda 1. Introduction to Mistake-Proofing (≈ 30 min) 2. Process Mapping & Exercise (≈ 35 min) 3. The Building Block & Exercise (≈ 35 min) 4. Process FMEA & Exercise (≈ 100 min) 5. Risk Analysis & Exercise (≈ 45 min) 6. Human Errors and Poka-Yoke & Exercise (≈ 60 min) 7. Process Control Plan & Exercise (≈ 60 min) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  16. 16. OPERATIONAL EXCELLENCE C O N S U L T I N G 46 February 26, 2014 – v 4.0 Process FMEA - Example for Occurrence Ranking Rank Probability of Failure Mode Occurrence Possible Failure Rates PPM*) Failure rate ppk 1 Remote: Failure is unlikely. No failures ever associated with almost identical processes. ≤ 1 1 out of 1 000 000 ≥ 1.67 2 Very Low: Only isolated failures associated with almost identical processes. ≤ 7 1 out of 150 000 ≥ 1.50 3 Low: Isolated failures associated with similar processes. ≤ 64 1 out of 15 000 ≥ 1.33 4-6 Moderate: Generally associated with processes similar to previous processes which have experienced occasional failures, but not in major proportions. ≤ 500 ≤ 2700 ≤ 12 500 1 out of 2000 1 out of 400 1 out of 80 ≥ 1.17 ≥ 1.00 ≥ 0.83 7-8 High: Generally associated with processes similar to previous processes that have often failed. ≤ 50 000 ≤ 125 000 1 out of 20 1 out of 8 ≥ 0.67 ≥ 0.51 9-10 Very high: Failure is almost inevitable. ≤ 333 000 ≥ 333 000 1 out of 3 ≥ 1 out of 2 ≥ 0.33 < 0.33 Please make sure that the Ranking Scheme reflects your organization’s needs. Otherwise, revise the Ranking Scheme accordingly. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  17. 17. OPERATIONAL EXCELLENCE C O N S U L T I N G 49 February 26, 2014 – v 4.0 Risk Priority Number (RPN): For higher RPN’s the team must undertake efforts to reduce this calculated risk through corrective action(s). In general practice, regardless of the resultant RPN, special attention should be given when severity is high. 0001)()()( ≤••= DetOccSevRPN Process FMEA - Risk Priority Number This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  18. 18. OPERATIONAL EXCELLENCE C O N S U L T I N G 52 February 26, 2014 – v 4.0 Actions that will influence the Process FMEA risk evaluation are: Corrective & Preventive Actions OS D Redesign the process YM Y Redesign the product MM M Improve current control NN Y Change material parts MN M Change the field environment NM N Improve reliability program YN Y Improve employee training MN Y Implement FMEA program YY Y Implement SPC program YN Y Improve quality plan YN Y Y = Yes, M = Maybe, N = No Process FMEA - Action Planning This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  19. 19. OPERATIONAL EXCELLENCE C O N S U L T I N G 55 February 26, 2014 – v 4.0 Human Errors are inevitable !!! Errors can´t be avoided. People will always make mistakes. Human Errors - Dealing with Human Errors Human Errors can be eliminated !!! Any kind of mistake people make can be reduced or even eliminated. People make fewer mistakes if they are supported by a production system based on the principle that human errors can be prevented. An organizations must establish a mistake-proofing mindset that promotes the belief that it is unacceptable to allow for even a small number of product or service defects caused by human errors. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  20. 20. OPERATIONAL EXCELLENCE C O N S U L T I N G 58 February 26, 2014 – v 4.0 1. Work Progress Understanding Start End 2. Work Object Selection 3. Recognition of Work Object’s State 4. Recognition of the Motion to be done on the Work Object 6. Motion Execution 5. Recognition of the Danger in the Motion Human Errors - The Human Work Model This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  21. 21. OPERATIONAL EXCELLENCE C O N S U L T I N G 61 February 26, 2014 – v 4.0 1. Failures in “Understanding the Work Progress” 1. Omission → What part of the process is prone to be omitted? 2. Excessive / Insufficient Repetition → What part of the process is prone to be excessively repeated? 3. Wrong Order or Sequence → In what wrong sequence can the process be executed? 4. Early / Late Execution → What execution can be early or late? 5. Execution of Restricted Work → What tasks could be executed by unauthorized personnel? The Human Work Model & The 16 Human Error Modes This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  22. 22. OPERATIONAL EXCELLENCE C O N S U L T I N G 64 February 26, 2014 – v 4.0 4. Failure in “Recognizing Correct Motion to be Done on Work Object” 10. Incorrect Holding → What object of the process are prone to mishandling? 11. Incorrect Orientation → What orientation error is prone to occur? 12. Incorrect Positioning → What positioning setting error is prone to occur? 13. Incorrect Motion → What motion or movement error is prone to occur? The Human Work Model & The 16 Human Error Modes This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  23. 23. OPERATIONAL EXCELLENCE C O N S U L T I N G 67 February 26, 2014 – v 4.0 1. Work Progress Understanding Error Modes (1) - (5) Start End 2. Work Object Selection Error Modes (6) - (7) 3. Recognition of Work Object’s State Error Modes (8) 4. Recognition of the Motion to be done on the Work Object Error Modes (10) - (13) 6. Motion Execution Error Modes (14) - (16) 5. Recognition of the Danger in the Motion Error Modes (9) The Human Work Model & Error Modes This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  24. 24. OPERATIONAL EXCELLENCE C O N S U L T I N G 70 February 26, 2014 – v 4.0 iii. Assembling the part onto the sub-assembly product 1. Forgetting to assemble the part (mode 1: omission) 2. Assembling onto the wrong sub-assembly product (mode 6: incorrect selection) 3. Holding a damageable part of the sub-assembly product (mode 10: incorrect holding) 4. Assembling the part in the wrong position (mode 11: incorrect positioning) 5. Assembling the part the wrong way around (mode 12: incorrect orientation) 6. Inaccurately assembling the part (mode 15: inaccurate motion) Human Errors - Human Work Model Example This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  25. 25. OPERATIONAL EXCELLENCE C O N S U L T I N G 73 February 26, 2014 – v 4.0 Variation Control Use of special jigs, fixtures, or assembly tools that reduce the variation of how parts are manufactured or assembled Workplace Organization Error prevention by proper organization of the workplace or work station; e.g. implementation of a 5S Visual Workplace Program Identification Errors are prevented by use of clearly written, visual and easily available materials, work instructions and tools Process Checks Performance of specific in-process checks to prevent errors Poka - Yoke Devices Ensures mistake and errors cannot become defects by automatically detecting error conditions and immediately rejecting the part or shutting down the process. Poka- Yoke devices work best when a specific step must be taken to re-start the process once a mistake or error has been detected. Five Key Mistake-Proofing Methods This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  26. 26. OPERATIONAL EXCELLENCE C O N S U L T I N G 76 February 26, 2014 – v 4.0 Requirements: • The outcome of the process or routine must be known in advance so as to have a standard for comparison • There must be an ability to create a break between cause and effect in the process so as to provide an opportunity to insert a Poka-Yoke Poka-Yoke devices work best in environments or processes: • requiring substantial operator skill • where training or turnover cost is high • with frequent interruptions and distractions • with a consistent set of mixed products • with similarly positioned or configured parts, controls or tools • requiring replacement or orientation of parts in order to prevent mispositioning Where to use Poka-Yoke Devices? This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  27. 27. OPERATIONAL EXCELLENCE C O N S U L T I N G 79 February 26, 2014 – v 4.0 1. Guide Pins Guide pins of different sizes and/or shapes and placed in the proper locations ensure that parts are being assembled correctly by providing the operator feedback when a mistake has been made. Guide pins can also be used in jigs to ensure proper positioning of the part. Applications • Proper alignment of a work piece • Proper orientation of a work piece Features • Easy to develop & implement • May be the result of DFA and DFM activities (Product Quality Planning) Human Error Prevention • wrong order, incorrect selection, incorrect positioning, incorrect orientation, … Seven Best Poka-Yoke Devices – Guide Pins This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  28. 28. OPERATIONAL EXCELLENCE C O N S U L T I N G 82 February 26, 2014 – v 4.0 3. Limit Switches Limit switches are electro-mechanical devices that are activated or deactivated when an object comes in contact with them. They are used to detect the presence or absence of an object. Applications • Proper positioning of safety devices • Detection presence or absence of an object • Positioning of a work piece Features • Requires physical contact Human Error Prevention • Omission, excessive/insufficient repetition, incorrect selection, incorrect counting, incorrect positioning, incorrect orientation Seven Best Poka-Yoke Devices – Limit Switches This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  29. 29. OPERATIONAL EXCELLENCE C O N S U L T I N G 85 February 26, 2014 – v 4.0 5. Vision Systems Vision systems use cameras to look at a surface and then compare the surface viewed to a “standard” or reference surface stored in the computer. They can be used to detect the presence or absence of an object, the presence of defects, or to make distance measurements. Applications • Missing or incorrect parts in an automated assembly line • Poor quality surfaces or components • Correct orientation of parts or labels • Ensure correct relative position • Color detection Features • Non-contact - Need to have sufficient light - Flexible (can be reprogrammed for a variety of applications) - Compact systems are now available. Human Error Prevention • Omission, incorrect selection, incorrect positioning, incorrect orientation, misrecognition, … Seven Best Poka-Yoke Devices – Vision Systems Checking for Label Presence, Color, Orientation, & Alignment. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  30. 30. OPERATIONAL EXCELLENCE C O N S U L T I N G 88 February 26, 2014 – v 4.0 Human Errors → Mistake-Proofing Examples SIM cards only fit one way. The right way. Expose your team to (simple) everyday Mistake-Proofing devices and examples and make them think about how they could use these concepts in their own process and work area. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  31. 31. OPERATIONAL EXCELLENCE C O N S U L T I N G 91 February 26, 2014 – v 4.0 Human Errors → Mistake-Proofing Examples It only fits one way by using guide pins and asymmetric product design. Good Product Quality Planning. → Guide “Pin” Human Error prevention through a visual workplace. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  32. 32. OPERATIONAL EXCELLENCE C O N S U L T I N G 94 February 26, 2014 – v 4.0 Human Errors → Mistake-Proofing Examples Well Designed garage door openers have two safety features: (1) a contact safety reverse feature, which opens the door if it hits a person or object, and (2) an infrared beam across the doorway that causes the door to reverse automatically if a person or pet who passes through the beam. A company called Metric Blue offers metric bolts tinted blue. Why blue? So that when you have mixed metric and inch-series parts and fasteners it is easier to determine which standard you are working with. Company literature says, “by differentiating the metric fasteners (and tools) through our "blue" coating, we've eliminated the risk of failure or accidents due to mismatched components.” This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  33. 33. OPERATIONAL EXCELLENCE C O N S U L T I N G 97 February 26, 2014 – v 4.0 “Mistake Proofing” Course Agenda 1. Introduction to Mistake-Proofing (≈ 30 min) 2. Process Mapping & Exercise (≈ 35 min) 3. The Building Block & Exercise (≈ 35 min) 4. Process FMEA & Exercise (≈ 100 min) 5. Risk Analysis & Exercise (≈ 45 min) 6. Human Errors and Poka-Yoke & Exercise (≈ 60 min) 7. Process Control Plan & Exercise (≈ 60 min) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  34. 34. OPERATIONAL EXCELLENCE C O N S U L T I N G 100 February 26, 2014 – v 4.0 Process: Name of the process to be controlled Process Step: The process steps of the process to be controlled Characteristic (Product/Process): Name of the characteristic of a process step or a product, which will actually be controlled. Specification: Actual specification, which has been set for the characteristic to be controlled. This may be verified e.g. in standards, drawings, requirements or product requirement documents. Control Limits: Control limits are specified for characteristics that are quantifiable and selected for trend analysis (x-bar/R, x/mR, p charts). When the process exceeds these limits, corrective actions are required. Measurement System: Method used to evaluate or measure the characteristic. This may include e.g. gages, tools, jigs and test equipment or work methods. An analysis of the repeatability and the reproducibility of the measurement system must first be carried out (e.g. Gage R&R Study). Process Control Plan - Template This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  35. 35. OPERATIONAL EXCELLENCE C O N S U L T I N G 103 February 26, 2014 – v 4.0 The OCAP is a systematic and ideal problem-solving tool for process problems because it reacts to out-of-control situations in real time. OCAPs standardize the best problem-solving approaches from the most skilled and successful problem solvers (experts/operators). The OCAP also allows (and requires) off-line analysis of the terminators to continually improve OCAP efficiency. Some Benefits of Out-of-Control-Action-Plans This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
  36. 36. OPERATIONAL EXCELLENCE C O N S U L T I N G 106 February 26, 2014 – v 4.0 “Mistake Proofing” Course Agenda 1. Introduction to Mistake-Proofing (≈ 30 min) 2. Process Mapping & Exercise (≈ 35 min) 3. The Building Block & Exercise (≈ 35 min) 4. Process FMEA & Exercise (≈ 100 min) 5. Risk Analysis & Exercise (≈ 45 min) 6. Human Errors and Poka-Yoke & Exercise (≈ 60 min) 7. Process Control Plan & Exercise (≈ 60 min) This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/opex-mistake-proofing-training-module-600
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