What is Error Proofing?
Error proofing is the implementation of fail-safe mechanisms to prevent a process from producing defects eliminating the possibility of human error!
How much are you paying not to error proof?
What about customer satisfaction?
Manufacturer X is building up automobile instrument panels and they continue to ignore issues caused by the operator.
Application – Install four fasteners in vent duct
Problem – If an operator missed a vent duct screw the duct would rattle when the blower was turned on
Resolution – The only way to correct the rattling noise was to take apart the dash and install the missing screw
Cost – 2 hours of labor, $0.10 screws and an annoyed customer
Solution – The customer was able to correct their missing fastener issue by implementing a line stop which is controlled by a wireless qualifier and counts each screw the operator correctly installs using a wireless tool.
When to consider error proofing?
- Best Practice – Build into the initial design
- Quality Critical Applications
- When consequences of an error are expensive or dangerous
- Now – It’s never too late
- Incorrect tool
- Missed fastener
- Improper tightening
- Wrong specification
- Wrong procedure
- Wrong tool selection
- Mechanical failure
- Improper materials
- Out of tolerance
- Defective materials
- Insufficient lubricant
Advantages of Error Proofing
- Improve product quality
- Increases productivity
- Improve work safety
- Reduce/eliminate repair work
Increases Overall Profits!