Advanced Error and Mistake Proofing

2011

Presented By:
Jim Gajda
Dave Massengill
Arturo Portillo Gomez
Presenter

Jim Gajda

2
 Pre Test
1. From the list below, what statement best describes error proofing:
a. Will have few or no mistakes
b. Ensures that a mistake cannot be made
c. Ensures higher customer satisfaction and is linked to the operation that follows it
d. Provides immediate feedback and corrective action and helps the operator reduce
or eliminate mistakes
e. Improves the operation

2. When trying to prevent a defect from occurring, the first consideration should be _____.
a. 100% inspection
b. Statistical process control
c. Mistake proofing
d. Error proofing

3. A warning buzzer sounds if a part is loaded into a weld fixture incorrectly, but the defect
can still be made, this is an example of _______.
a. Mistake proofing
b. Error proofing
c. Fail safe
d. Fool proofing
 Pre Test

4. Causes of Errors/Mistakes:
a. Human Error
b. Component Failure
c. Machine Failure
d. Process Failure
e. a & c
f. All the above

5. When EMP are used effectively, the results are_____.

a. Decreased rework, scrap and material waste
b. Increased cycle time
c. Decreased process variation
d. Both a & c
e. Both a & b

6. What EMP category would you use a visual aid/procedure for?

a. Mistake proofing
b. Error proofing
c. Detection
d. Procedural
 Pre Test

7. Mistake Proofing is designing a potential failure or cause of failure out of a product or

process?
a. True
b. False

8. Error Proofing is reactive?

a. True
b . False

9. Detection is more effective than Mistake Proofing?

a. True
b. False

10. Inspection is more effective than Mistake Proofing?

a. True
b. False
Test

Search and count the letter “f” and “F” in the following paragraphs

f and F
90 Seconds

F= f= TOTAL=
Inspection Test

The necessity of training farm hands for first-class farms in the

fatherly handling of farm livestock is foremost in the minds of
farm owners. Since the forefathers of the farm owners trained the
farmhands for first-class farms in the fatherly handling of farm
livestock. The farm owners feel they should carry on with the
family tradition of training farm hands of first-class farms in the
fatherly handling of farm livestock because they believe it is the
basis of good fundamental farm management. The Detroit Red
Wings are in the first place. First Production Shipment
Certification plan requires the Supplier to provide statistical
evidence of the first 2000 parts shipped. The FPSC quantity may
be adjusted. It seams rather incongruous that is a society of
super-sophisticated communication, we often suffer from a
shortage of listeners. Frequent flyer is very good with only one
airline Freedom air.
f= F= TOTAL=
Inspection Test – Results

The necessity of training farm hands for first-class farms in the

fatherly handling of farm livestock is foremost in the minds of farm
owners. Since the forefathers of the farm owners trained the
farmhands for first-class farms in the fatherly handling of farm
livestock. The farm owners feel they should carry on with the
family tradition of training farm hands of first-class farms in the
fatherly handling of farm livestock because they believe it is the
basis of good fundamental farm management. The Detroit Red
Wings are in the first place. First Production Shipment
Certification plan requires the Supplier to provide statistical
evidence of the first 2000 parts shipped. The FPSC quantity may
be adjusted. It seams rather incongruous that is a society of
super-sophisticated communication, we often suffer from a
shortage of listeners.
Frequent flyer is very good with only one airline Freedom air.
f = 47 F= 4 TOTAL= 51
Inspection Test - Results

Can We Really Rely on Inspection

?
Cost of NCT without Error Proofing

When evaluating the cost of error proofing a feature

upfront, consider this:

• Minimum cost for a single NCT = 6 hours administration

charge ($285) + cost of scrap part
• This does not include expedited shipment to replace
stock
• This does not include pick and replace charges at the
assembly plant

10
Cost of 3CPR without Error Proofing

When evaluating the cost of error proofing a feature upfront, consider

this:

• Level 1 3CPR sort by PIC = $28 per hour

• Level 2 3CPR sort by PIC = $33 per hour
• To sort a day’s production at SHAP, is 1000 pieces. Assuming 4
hours of sort time = $112
• PIC has to certify the next shipment, so if it arrives the next day and
assumed to be the same 1000 pieces = $112
• A fork truck driver to move parts = $45/ hour x 2 hours = $90
• Total to sort and move parts = $314
• An NCT will accompany a Level1 3CPR so add at least the $285
minimum, total cost = $599
• This does not include the cost to expedite a shipment.
11
Cost of Yard hold without Error Proofing
When evaluating the cost of error proofing a feature upfront, consider
this:

• Yard hold costs = $10.50 per vehicle per day plus repair costs
• For example 60 cars is one of production for SHAP.
• To hold this hour of production is 60 x $10.50 = $630 per day
• A one hour repair on each car is 60 x $45 = $2700
• Total of $3330 not including any part expedites for vehicle repairs or
logistical costs if vehicles have to be moved off site for repair.
• At least a Level 1 3CPR and a NCT will accompany the yard hold so
add the $599 estimate from the last slide = $3929
• This is for 60 vehicles, yard holds are generally a much higher
magnitude of vehicles, a full yard on hold can be thousands of cars
resulting in a million dollars of expense or more.

12
Objective
• Understand the concept of Error/Mistake Proofing

• Understand the difference between Error Proofing and Mistake Proofing

• Build knowledge on Error Mistake Proofing Strategy model

Error
Proofing

Mistake
Proofing

Procedure
Objective Continued

• Review the EMP PSO Element Requirements

• Review actual EMP examples

Error vs. Mistake Proofing
• Designing a potential failure
or cause of failure out of a
product or process; the
defect cannot be made (e.g.
one way assembly)
• Proactive
• PREVENTION
• Change to an operation/part
that helps the operator
reduce or eliminate defects
or prevent the defect from
continuing downstream (e.g.
warning)
• Reactive
• DETECTION
Error/Mistake Proofing Examples

Problem Description Error Proof

Vehicle nameplates rotated 180 degrees causing them to

be installed upside down when both holes and emblem pin
sizes are of equal size.
Error/Mistake Proofing Examples

Solution

Create a larger hole on the right-hand side of the

install area and a smaller hole on the left-hand side.
A larger pin is placed on the right-hand side of the
back of the nameplate with a smaller pin on the left.
The nameplate can only be installed in the proper
orientation.

Good:
different
size holes
Error/Mistake Proofing Examples

Problem Description Mistake Proof

Rad hoses can be installed engine-side to radiator or

radiator-side to engine and not in the correct orientation.
Error/Mistake Proofing Examples

Solution

Add the letters “RAD” and “ENG” to the ends that go to

the radiator and engine, respectively. Also, added a white,
thick line (mark) to each end to line up with a designated
point on engine and radiator.
Examples

Problem Mistake Proofed Error Proofed

Not wearing seatbelts
Warning light or chime Vehicle cannot start

Unfilled Cup
“CUP IS FILLING” light Dispensing door will not
open until cycle is
complete

Lack of Fuel
Fuel Indicator light or Wheel locked or
blink machine cannot start
Causes of Errors/Mistakes

Human Error Component Failure

 Forgetfulness  Wrong multiple part chosen
 Misunderstanding  No unique difference from similar parts
 Experience  Incorrect part orientation
 Misidentification  Omitted parts
 Standards not known  Parts installed in wrong location
 Willful  Wrong number of parts
 Inadvertent  Parts installed on wrong side of line
 Intentional
 Wrong tool usage
Defects
 Break downs  Fixture not used
 Wrong settings  Mis-routing
 Poor calibration  Incorrect sequencing
 Excessive variation  Incorrect work instruction
 Setup errors  Poor part presentation
 Omitted processes
 Errors enter process
Machine Failure Process Failure
Control Levels

Least effective Most effective

Procedural Mistake Proofing Error Proofing

mistake mistake mistake
mistake mistake mistake mistake
mistake mistake
mistake mistake
mistake mistake
mistake mistake
mistake mistake
mistake
mistake mistake

mistake
mistake mistake
mistake
mistake

defect defect defect

PLANT
defect
defect CUSTOMER
defect defect
defect
EMP Categories

HIGH
Product Design
Error Proofing E
Process Design f
f
e
c
t
Control i
Mistake Proofing Warning v
e
Operational n
e
s
s

Procedural Visual Aid/Procedure

LOW
EMP Strategy Steps

Error Proofing Steps

N
G
I
Error Can we design the failure mode out of the product? N
E
Proofing if not…
E
R
I
N
Can we design the failure mode out of the process G
-Product Design
using error proof pins, guide pins, locator pins, anti-
-Process Design
rotational blocks, etc?

M
A
N
U
F
A
C
T
U
R
I
N
G
EMP Strategy Steps

Mistake Proofing Steps E

Error Can we support the operator by detecting
N
G
Proofing defects through the use of electronic devices
I
N

such as limit switches, proximity switches,

E
E
-Product Design torque transducers, etc
R
I
-Process Design N
Warning (audible, visible, …) G

Contain in station
Mistake if not…
Proofing
M
-Control Can we support the operator with A
N
-Warning simple tooling or fixtures? U
F
-Operational if not… A
C
T
U

Can we support the operator by R

I

visual means such as color coding, N

G

stampings, markings etc?

Strategy for PFMEA and Problem Resolution

Can have procedural,

N
G

Error detection and mistake I

N
proofing in process and E
Proofing still ship bad parts.
E
R
I

-Product Design N
G

-Process Design
Mistake M
A
Proofing N
U
F
A
-Control C
T
-Warning U
R
-Operational I
N
G
Procedure
Procedural
•Can we support the operator with a visual -Visual Aids/Procedure
aid, correct sequencing or procedure?
EMP and PFMEA

• EP for FM with Severity =,> 8

• EMP for Special Characteristics

• EMP should be used for ALL

reworked and repaired product.

• EMP included in the PM Plan.

EMP: Error Mistake Proofing

EMP and PFMEA element 13
Mistake Proofing Devices should have
Verification Samples (red rabbits)
• Developed failure modes identified
in the PFMEA.

• Tested on production line.

• Used start-end shift, changeover

major disruptions, tooling
regularly
maintenance, etc.

• Maintained marked, labeled, controlled.

• Back-up contingency plan if EMP is

plan (EMP) not operable.
28
 Benefits

• When Error Proofing and Mistake Proofing are used

effectively, the results are:

– Decreased rework and scrap

– Effective feedback to the operator
• leading to decreased cycle time
– Decreased process variation
– Reduce waste
– Improve delivery

REDUCE OVERALL COST OF QUALITY

 EMP Guidelines
Error/Mistake Proofing Guideline
Below are basic questions that will help you focus your analysis of Error Proofing and Mistake Proofing. This is not a
comprehensive list of everything that should be reviewed, only a guideline. When attempting to evaluate whether
Error Proofing and Mistake Proofing were executed properly, ask the following questions:
• Consider all Error or Mistake Proofing opportunities
• Could this part or process be error proofed instead of mistake proofed?
• Is the Error or Mistake Proofing device simple and cost effective?
• How has an FMEA been used to identify potential failure modes?
• Has a risk analysis been performed?
• Has a Process Flow Diagram/Risk Analysis been used to identify high risk elements and actions required?
• Who was on the team used to error/mistake proof the part or process and was the operator involved?
• How did you decide on which operations to mistake proof? Did you use the Process FMEA as an input in your
selection of those operations?
• Does the recommended process allow employees to bypass the Mistake Proofing device? Does the
recommended process shut down or notify via alarm or lights that the Mistake proofing device has been missed?
• How will you track your results and measure success?
• Were the Mistake Proofing devices/set-ups completed and available for plant try-out during pilot builds?
• What are the estimates of cost and benefits of implementing a solution?
• Have you documented your Error Proofing and Mistake Proofing in the “Actions Taken” column of your Design
FMEA and/or Process FMEA?
• Have you documented your solutions on a Control Plan?
• Is there a preventive maintenance program which insures that all devices are working? When the device is
inoperative, is it fail safe so that all good parts are rejected rather than bad parts accepted?
New Presenter

Dave Massengill

31
Mistake Proofing Examples
Defect produced but detected in station
Control Warning
• automatically shuts down an warning (visible, audible) to
operation to prevent defects the operator of the defect or
from continuing in the incorrect process
process
process stopped when defect
detected
Example Example
Nutrunner checks for torque, if torque not Nutrunner checks for torque, if torque not met:
met:
Visual given to operator, such as:
Pallet would not be released from station 1. green light to indicate proper torque
without: 2. red light to indicate improper torque
1. correcting error
2. labeling part as defect (no manual
release allowed)
Mistake Proofing Examples

Operational
• parts color-coded, stamped/marked, or has
distinguishing feature
• part selection lights
• part presentation

Part selection lights

Stamping /marking
Color-coding
Error/Mistake Proofing Examples
Problem Description: Missing Front End Module (FEM) components.
Front End Module assembly process in many cases depends on the operator to
complete the assembly of the components and avoid missing one of them that
can lead to a Quality Issue at Chrysler Assembly Plant.
Error/Mistake Proofing Examples

Solution: Missing
FEM components
are identified in the
PFMEA and a poka
yoke was improved
as well as the
working station to
detect the
presence of these
components. If
one of them was
missing the station
would be locked.
Error/Mistake Proofing Examples

Working station improved with poka yokes and it automatically detects the
presence of components with sensors showing the green light for presence and
allowing the FEM carrier to continue to the next station, otherwise it is locked.
New Presenter

Arturo Portillo

37
Error/Mistake Proofing Examples
PSOC (Power Steering Oil Cooler).
Clamps location on tube/hose assembly.
Error/Mistake Proofing Examples
Problem Description:
Current controls for PSOC Hose Clamps did not detect clamps position
and did not detect clamps presence.
Error/Mistake Proofing Examples
PSOC

HOUSING

CLAMP SENSOR SENSOR

PLUNGER
HOSE

Solution: Plunger/Sensor is inside a fixed housing allowing only travel of

the plunger when it is in contact with the clip. If clip is outside the window
of the housing for location of clamp, the plunger will not activate the sensor
to accept the part as conformance.
 Error/Mistake Proofing Examples

Solution:
Poka-Yoke Fixture for
PSOC Hose/Clamp
assembly:
Presence and
Position. If the clamp PLUNGER
is in the correct
position it will force
the plunger back to
trigger a sensor for SENSOR
station acceptance. If
the clamp is not in
the correct position it
will hit the exterior
tooling and not push
the plunger back. HOUSING
Error/Mistake Proofing Examples
Problem Description: Front End Module (FEM) with incorrect ECM component.
Front End Module was shipped to Chrysler Assembly Plant with the incorrect
version of the Engine Cooling Module (ECM) and bar code label.
 Error/Mistake Proofing Examples
Solution: Install a fixed scanner in-station and link to PLC.

Screen showing
yellow before the
ECM is scanned
Error/Mistake Proofing Examples

Once ECM is
installed, the
ECM barcode
label is
automatically
scanned and
the signal is
sent to the PLC
to check P/N
according to
EBOM in order
to accept the
ECM barcode label ECM in-station.
Error/Mistake Proofing Examples

Screen
turns
Green
after ECM
is
scanned.

Line will
stop if
wrong
ECM is
installed.
New Presenter

Jim Gajda

46
 Post Test

1. From the list below, what statement best describes error proofing:
a. Will have few or no mistakes
b. Ensures that a mistake cannot be made
c. Ensures higher customer satisfaction and is linked to the operation that follows it
d. Provides immediate feedback and corrective action and helps the operator reduce
or eliminate mistakes
e. Improves the operation b. Ensures that a mistake
cannot be made
2. When trying to prevent a defect from occurring, the first consideration should be _____.
a. 100% inspection
b. Statistical process control
c. Mistake proofing d. Error Proofing
d. Error proofing

3. A warning buzzer sounds if a part is loaded into a weld fixture incorrectly, but the defect
can still be made, this is an example of _______.
a. Mistake proofing
b. Error proofing
c. Fail safe a. Mistake proofing
d. Fool proofing
47
 Post Test

4. Causes of Errors/Mistakes:
a. Human Error
b. Component Failure f. All the above
c. Machine Failure
d. Process Failure
e. a & c
f. All the above

5. When EMP is used effectively, the results are_____.

a. Decreased rework, scrap and material waste
b. Increased cycle time
c. Decreased process variation d. Both a & c
d. Both a & c
e. Both a & b

6. What EMP category would you use a visual aid/procedure for?

a. Mistake proofing
b. Error proofing
c. Detection
d. Procedural
d. Procedural
48
 Post Test

7. Mistake Proofing is designing a potential failure or cause of failure out of a product or

process?
a. True b. False
b. False

8. Error Proofing is reactive?

a. True
b . False b. False
9. EMP should be used for ALL reworked and repaired product.
a. True
b. False a. True
10. Inspection is more effective than Mistake Proofing?
a. True
b. False b. False

49
Wrap up

50