Mistake Proof It ! Mistake-proofing techniques, Training

Mistake - Proofing

Mistake-Proof It!

Web-Based • LAN-Based • CD-ROM

Course Description

Why Does My Company Need This Program?

Course Description

Over 100 mistake-proofing examples
Traditional Poka Yoke techniques combined with innovative application tools and strategies

What would happen if you could eliminate mistakes in your manufacturing operations? Impossible you say? Not if you implement mistake-proofing techniques. When you eliminate mistakes everything you make will be made right the first time; you will have no scrap, no rework, and no disappointed customers.

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Mistake-Proof It! teaches engineers, supervisors, technicians, and operators how to develop and implement mistake-proofing techniques. In addition to extensive content, exercises, and over a hundred examples of mistake-proofing in a variety of industries, a key feature of the program is the Mistake-Proof It! Project Log. The Project Log will bring the training to life by walking learners through a series of questions and exercises to apply what they are learning to their own mistake-proofing problem. Not only will employees learn mistake-proofing techniques, but they will begin using the techniques as they are going through the training.

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Course Objectives

To illustrate and emphasize why 99.9% is not good enough and why mistakes must be eliminated for good.
To help learners understand different mistake-proofing techniques.
To demonstrate how mistake-proofing is an integral part of an overall Quality Improvement Process.
To provide numerous examples of Mistake-Proofing.

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Intended Audience

Engineers, supervisors, operators.

Time To Complete

5 to 7 hours.

Course Outline

Mistake-Proof It! is divided into four units: Mistake-Proofing Primer, Effects of Mistake-Proofing, Implementing Mistake-Proofing Solutions, Mistake-Proofing in Action.

Mistake-Proof It! - 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

Mistake-Proofing Challenge

An assessment of the learner’s 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 sensory alert aids to achieve a sensory alert effect.

Unit Test

Mistake-Proofing Challenge

An assessment of the learner’s progress in this unit.

Unit 3 - Implementing Mistake-Proofing Solutions

Lesson 1 Integrating Mistake-Proofing & Problem-Solving	Applying standard team problem-solving techniques to mistake-proofing projects.
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 Mistake-Proofing Challenge	An assessment of the learner’s 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 then in high volume operations.

Eight 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.

Eight 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.

Eight 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.

Eight 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.

Eight real life examples of mistake-proofing solutions to aid equipment set-up and speed changeovers.

Lesson 6

Mistake-Proofing in the Office

Mistake-proofing is not just for plant operations.

Eight real life examples of mistake-proofing solutions in the office.

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Why Does My Company Need This Program?

If you are already doing mistake-proofing training

One of the most difficult things about mistake-proofing is being able to "think outside of the box." If you are already doing mistake-proofing, but are looking for better mistake-proofing solutions, you will find that Mistake-Proof It! will give you a wide range of fresh and innovative ideas that you can apply in your company.

If you are not already doing mistake-proofing training

Mistake-Proof It! will give you a solid understanding of mistake-proofing techniques as well as provide you with extensive examples of mistake-proofing in a variety of situations. This will help you better understand how mistake-proofing can be applied in your company.

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Mistake Proof - It Web Based Training