ppt mistake proofing

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Mistake Proofing By: Krishna Kant FPB0911/055 02/06/2022 Indian Business Academy 1

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Page 1: PPt Mistake Proofing

04/11/2023Indian Business Academy 1

Mistake Proofing

By:Krishna Kant FPB0911/055

Page 2: PPt Mistake Proofing

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Understand the difference between errors and defects

Understand how defects originate Recognize the elements of source inspection

and its role in defect elimination Identify key mistake proofing devices Show mistake proofing as a proactive tool, and Show how mistake proofing fits into the Six

Sigma methodology.

The objectives:

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• Mistake proofing is a technique for eliminating errors.

• It is based upon the premise that it is good to do something right the first time.

• It is even better to make it impossible to do it wrong

the first time. • The idea is to make it impossible to make a mistake.

• You may also hear the term, Poka-Yoke or Error Proofing applied to mistake proofing.

Overview

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• Controls the features in the product or process to prevent or mitigate the occurrence of errors.

• Requires simple, inexpensive inspection (error detection) at the end of each successive operation to discover and correct defects at the source.

The concept of Mistake-Proofing involves

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• Elimination

• Replacement

• Prevention

• Facilitation

• Detection

• Mitigation

Principles for Mistake Proofing

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Elimination

It seeks to eliminate the possibility of error by redesigning the product or process so that the task or part is no longer necessary.

Example : Siren in the TVS mopeds.

Contd…

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Replacement

It substitutes a more reliable process to improve consistency.

Examples: Use of robotics or automation that prevents a manual assembly error.

Contd…

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Prevention

It engineers the product or process so that it is impossible to make a mistake at all.

Example : Bank angle sensor in bikes.

Contd…

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Facilitation

It employs techniques and combining steps to make work easier to perform.

Examples : GPS system in cars.

Contd…

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Detection

It involves identifying an error before further processing occurs so that the user can quickly correct the problem.

Examples : Sensor in the luxurious cars.

Contd…

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Mitigation

It seeks to minimize the effects of errors.

Example : Fuses to prevent overloading circuits resulting from short circuit.

Contd…

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Colors and color coding Ex. - Credit card receipts are almost always designed so the customer gets the yellow copy and the merchant gets the white copy.

Use of shapes Ex. - Stop signs are always octagonal.

Auto-detection Ex. - Word processors come with spell checkers. These reduce errors considerably.

Strategies employed to minimize mistakes

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• ATM customers complain that they never know the right way to insert their ATM card, and it usually takes a couple of tries to get it right.

• A local bottling company wants to make sure that all bottles are filled with exactly the right amount of soda.

• A large pharmaceutical company is trying to develop a way to assure elderly people living alone take their prescription medicine at the right time and in the correct dosage.

Mistake Proofing Challenges

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3.5 inch diskette cannot be inserted unless diskette is oriented correctly. This is as far as a disk can be inserted upside-down.

The beveled corner of the diskette pushes a stop in the disk drive out of the way allowing the diskette to be inserted. This feature, along with the fact that the diskette is not square, prohibit incorrect orientation.

Example of Mistake Proofing

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File cabinets can fall over if too many drawers are pulled out.

For some file cabinets, opening one drawer locks all the rest, reducing the chance of the file cabinet tipping.

Example of Mistake Proofing

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Automobile controls have a mistake-proofing device to insure that the key is in the on position before allowing the driver to shift out of park. The keys cannot be removed until the car is in park.

Example of Mistake Proofing

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Poka- yoke systems consist of three primary methods:

1. Contact2. Counting3. Motion-Sequence

• Each method can be used in a control system or a warning system.

• Each method uses a different process prevention approach for dealing with irregularities.

Poka- yokeMethods for Using

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• Do not have to be high tech.

• Passive devices are sometimes the best method. These can be as simple as guide pins or blocks that do not allow parts to be seated in the wrong position prior to processing.

• Take advantage of parts designed with an uneven shape.

• A work piece with a hole a bump or an uneven end is a perfect candidate for a passive jig. This method signals to the operator right away that the part is not in proper position.

Contact Methods

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• Used when a fixed number of operations are required within a process, or when a product has a fixed number of parts that are attached to it.

• A sensor counts the number of times a part is used or a process is completed and releases the part only when the right count is reached.

Counting Method

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• The third poka yoke method uses sensors to determine if a motion or a step in a process has occurred.

• If the step has not occurred or has occurred out of sequence, the sensor signals a timer or other device to stop the machine and signal the operator.

Motion Sequence Method

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Thank You