Mistake-Proofing Training

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Course Objectives

Unit 1:  Mistake-Proofing Primer

  • Understand the goal of mistake-proofing.
  • Know the language of mistake-proofing.
  • Recognize mistake-proofing solutions in everyday life and use these solutions as triggers for ideas to mistake-proof your processes.
  • Identify the five process input elements that exist in any process.
  • Recognize why errors are made.
  • See the value of improving processes so that mistakes are prevented instead of relying on inspection to find mistakes.

Unit 2:  Effects of Mistake-Proofing

  • Be able to rank the relative power of the different forms of mistake-proofing effects.
  • Recognize a forced control effect. Be able to apply:
    • Elimination
    • Combination
    • Guides
    • Process control
  • Have an understanding of some of the types of sensors available to achieve a shutdown effect.
  • Have an understanding of some of the types of devices available to create a mistake-proofing solution using a warning effect.
  • Know how to apply sensory alert effects to mistake-proofing.

Unit 3:  Implementing Mistake-Proofing Solutions

  • Learn to apply mistake-proofing solutions after the root cause has been found.
  • Be able to evaluate whether the mistake-proofing solution is practical, feasible, and cost-effective.
  • Learn how to build-in ways to assure your solution does not get overridden.
  • Evaluate the robustness level of your solution.
  • Become familiar with 10 improvement tools that complement the mistake-proofing process.

Unit 4:  Mistake-Proofing in Action

In this unit, recurring problems from a variety of industrial settings are explored and successful mistake-proofing solutions are shown.  The problems come from the following industrial settings:

  • High volume manufacturing.
  • Assembly operations.
  • A job shop environment.
  • Process industries.
  • Equipment set-up.
  • In the office.

The primary objective of this Unit is to expose you to a variety of mistake-proofing solutions to help you develop your own mistake-proofing solutions.

The secondary objective is to help you think through the solution presented and then identify what type of solution has been used.