Mistake-Proofing Training

Show Course Objectives

Course outline

Unit 1 - Mistake-Proofing Primer

Lesson 1

What is Mistake-Proofing?
  • Rewriting Murphy's Laws.
  • Exploring the source of mistakes.
  • The mindset necessary for mistake-proofing.

Lesson 2

Mistake-Proofing in Everyday Life
  • Common examples of mistake-proofing all around us.
  • Using these examples to trigger ideas at work.

Lesson 3

Why Errors Are Made
  • How process inputs create process outputs.
  • Why the root causes of errors must be identified.

Lesson 4

Inspecting vs. Mistake-Proofing
  • The limitations of inspection.
  • Why prevention is always more powerful than detection.

Lesson 5

How Mistake-Proofing Works
  • The language of mistake-proofing.
  • The role of teams in mistake-proofing efforts.

Unit Test

Challenge

An assessment of the learnerís progress in this unit.

Unit 2 - Effects of Mistake-Proofing

Lesson 1

Approaches to Mistake-Proofing
  • Exploring the 8 forms of mistake-proofing solutions.
  • Guidelines for selecting a mistake-proofing approach.

Lesson 2

Forced Control Devices
  • Delving into the four families of devices and methods used to achieve a forced control effect.

Lesson 3

Shutdown Devices
  • Examining 10 common families of sensors used to achieve a shutdown effect.

Lesson 4

Warning Devices
  • Investigating 4 families of audible alarms and 4 families of visual alarms used to achieve a warning effect.

Lesson 5

Sensory Alert Devices
  • A look at the use of color-coding, missing-in-action clues, and other aids to achieve a sensory alert effect.

Unit Test

Challenge

An assessment of the learnerís progress in this unit.

Unit 3 - Implementing Mistake-Proofing Solutions

Lesson 1

Integrating Mistake-Proofing & Problem Solving
  • How to incorporate mistake-proofing solutions into common problem-solving processes.

Lesson 2

Practical, Feasible, & Cost Effective Solutions
  • Assessment techniques for determining the practicality, feasibility, and cost-effectiveness of your mistake-proofing solutions.

Lesson 3

How to Keep Solutions from Being Overridden
  • Tips for keeping your mistake-proofing solution from being ignored or disabled.

Lesson 4

How Robust is Your Solution?
  • Assessment techniques for determining how robust your mistake-proofing solutions are.

Lesson 5

Complementary Tools
  • How to use ten continuous improvement tools to complement mistake-proofing efforts.

Unit Test

Challenge

An assessment of the learnerís progress in this unit.

Unit 4 - Mistake-Proofing in Action

Lesson 1

Mistake-Proofing in High Volume Manufacturing
  • Nowhere are the benefits of mistake-proofing more evident than in high volume operations.
  • 8 real-life examples of mistake-proofing solutions in a high volume environment.

Lesson 2

Mistake-Proofing in Assembly Operations
  • Mistake-proofing is a perfect tool to prevent assembly errors.
  • 8 real-life examples of mistake-proofing solutions in assembly operations.

Lesson 3

Mistake-Proofing in a Job Shop Environment
  • Mistake-proofing in short-run job shops can make the difference between profitability and bankruptcy.
  • 8 real-life examples of mistake-proofing solutions in a job shop environment.

Lesson 4

Mistake-Proofing in Process Industries
  • Mistake-proofing is at the core of complex chemical operations.
  • 8 real-life examples of common sense mistake-proofing solutions from the process industry that can trigger ideas to simplify your operation.

Lesson 5

Mistake-Proofing in Equipment Set-up
  • Mistake-proofing is an important element of set-up reduction.
  • 8 real-life examples of mistake-proofing solutions to aid equipment set-up and speed product change-overs.

Lesson 6

Mistake-Proofing in the Office
  • Mistake-proofing is not just for plant operations.
  • 8 real-life examples of mistake-proofing solutions in the office.