Lean Leader GB Series 10 - Mistake Proof a Process

Your Gateway to Operational Excellence
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LEAN LEADER TRAINING PACKAGE
Module 10 – Mistake Proof a Process

Mistake Proofing – Reality Check
1. No matter how good you are at finding
defects, no matter how thoroughly you
follow up with corrective action,
improving your defect inspection and
feedback processes will NOT prevent
defects from happening in the first place.
2. To prevent defects you must look at the
process to determine what condition
leads to the defect, then control that
condition.
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Defect Free – Zero Quality Control
Achieving ZERO defects
Principle 1
‘Defects are prevented by controlling the
performance of a process so it cannot produce
defects – even when a mistake is made by a
person’

Group Activity – Mistake Proofing
In groups of 2-3 identify how
you could mistake proof the
case study on the previous
page:
Time allowed – 20 minutes
Use the sheet below to collate your answers

Sources of non-conformance
1. Process
2. People
3. Machinery
4. Materials
5. Environment
Identify some of the sources of
non-conformance in your
work area.
Use the sheet below to collate your answers

Product Inspection-Three Approaches
Judgement
Inspection
Source
Inspection
Eliminating
defects by
catching and
fixing their
causes
Informative
Inspection
Discovers
defects but
does not
reduce them
Reduces defects
by informing the
process after they
happen

Developing Preventative Measures
Right First Time, Every
Time
Design a system or
process that can only be
done one way

Mistake Proofing Documents
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Testing and Validation
Use the problem you
highlighted on page 16
Design a testing and validation
strategy to ensure that your
process can achieve a “Right
First Time, Every Time” result.

Mistake Proofing Technique #3
Prevention
engineers the product or process so that
it is impossible to make a mistake at all.
Examples : Limit switches to assure a
part correctly placed or fixtured before
process is performed; part features that
only allow assembly the correct way,
unique connectors to avoid
misconnecting wire harnesses or cables,
part symmetry that avoids incorrect
insertion.

Mistake Proofing Technique #6
Mitigation
seeks to minimize the effects of errors.
Examples: fuses to prevent
overloading circuits resulting from
shorts; products designed with low-
cost, simple rework procedures when
an error is discovered; extra design
margin or redundancy in products to
compensate for the effects of errors

Some Day-to-Day Examples

Implementation – Permanent Solutions
Requires liaison with fellow staff
members to:
1. Have systems and procedures
changed
2. Train new skills and methods
3. Check progress

Workplace Project
– Design a Defect Out
Identify a defect in your work area
and design it out of the process.
Use the methodology in this
workbook as a guide.

Project Evidence – Part 3
Implement Permanent Fix
3.1 Liaise with relevant people to have
systems/procedures changed to
implement the solution
3.2 Liaise with relevant people to
implement the solution
3.3 Liaise with relevant people to ensurethe
workforce has the appropriate skill set
3.4 Follow through to ensure
implementation occurs

Workplace Project Presentation
Plan and present a project on what you have
learnt and what has been implemented in your
workplace. Be prepared to present this at the
next session.
• Form groups of 2 or 3 people
• Can be practical or formal presentation
• Mistake Proofing projects
• Defect Reduction Analysis example
• Impact of changes

Wrap Up
• Participants identify one key item that they
will remember from today’s session
• Don’t forget to bring your project
information to the next session for review
and assessment
• Good luck !

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Lean Leader GB Series 10 - Mistake Proof a Process