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Mistake Proofing Planning Sheet

 Process Map Complete?

FMEA Complete?

Process Step

Product/Service

1) Describe Defect and Defect Rate
Defect Description:

Date

Graph # Defects - Time

Rate of Defect Production
35%
30%

Defect Rate:
Defects

25%
20%
15%
10%
5%

Ju
l
Au
g
Se
p
O
ct
N
ov
D
ec

M
ar
Ap
r
M
ay
Ju
n

Fe
b

Ja
n

0%

Time

2) Identify the location where the defect is:
Discovered

Made

3) List the process steps where defects occur (1 step per box). - One standard element per planning sheet
A

B

C

D

E

4) For each defect-producing process step, list the defects which occur.
A
B
C
D

E

5) For each defect-producing process step, list the possible causes for the defect. Identify Red Flag Conditions.
A - why
B - why
C - why
D – why
E – why
A - why
B - why
C - why
D – why
E – why
A - why
B - why
C - why
D – why
E – why
A

Root Cause of the Error or Defect
C
D

B

E

6) Ideas to eliminate or detect the error. Indicate where in the process the defect or error should be detected or
prevented, either before, during or after it is made.
Eliminate cause of
A
B
C
D
E
Detect error as it is being made
A
B
C
D
E
Detect defect before it reaches next process step
A
B
C
D
E
7) Create a device
Description of
Improvements

IMPROVEMENT

IMPROVEMENT

Current Cond.

Device

Current Cond.

Device

Cost to Install:
Remarks:

Time to Install:
Date:

Cost to Install:
Remarks:

Time to Install:
Date:

Mistake Proofing Planning Sheet – Page 1

Team Members

Mistake Proofing Planning Sheet – Page 2 .