ERROR PROOFING VALIDATION LOG

Error Proofing Mechanism:________________________________________________________________________

Dept:____________________________ Operation:__________________________

DATE SHIFT/TIME EP MECHANISM INITIAL COMMENTS

WORKING?
(Y/N)

DISPOSITION
 ERROR PROOFING IMPLEMENTATION
FORM
PROCESS: PREVENT ERROR:

PROBLEM: DETECT ERROR:

SOLUTION:

DESCRIPTION OF PROCESS:

BEFORE IMPROVEMENT: AFTER IMPROVEMENT:

FOLLOW-UP PERSON:_________________________________ DATE:________________

 ERROR PROOFING WORKSHEET
PART NAME: PART NO.

DEPARTMENT: OPERATION NO.

SELECTION CRITERIA: RPN No.: Severity: Other:

Characteristic ID and
Description:

Error Proofing
Technique(s)

COST:

Alarm Mechanism:

Reaction Plan:

Error Proofing Function

Confirmation Method:

Check Interval:

Method of Performing Check Item Frequency Check Device

Quality Check in Event
That Error Proofing
Technique Stops
Functioning
 QUALITY WORKSHOP
DEFINITION OF QUALITY MEASURES - SHEET 1
1. COST OF QUALITY: A measure of the costs incurred to produce a quality product. May
include both value added and non-value added components. Although the Cost of Quality is
usually stated as a percentage of total sales, it may be easier to establish cost of quality in terms
of dollars or a percentage of production.
COST OF QUALITY is equal to or consists of:
1. Cost of prevention, plus
2. Cost of appraisal, plus
3. Cost of internal failures, plus
4. Cost of external failures
PREVENTION = Quality planning, quality training, quality system controls
and maintaining process capability studies, etc.
APPRAISAL = Any audits, 100% inspection, 100% testing.
INTERNAL FAILURES = Scrap, rework, sorting, quarantined inventory, engineering
permits / deviations.
EXTERNAL FAILURES = Returned sales, warranty, premium freight, customer
charges.

How to calculate:
Cost of Quality - Use the best available measure, such as scrap rate or dollars.
( Current State - Improved State ) X 100
Percentage Reduction =
Current State
Note: The maximum reduction allowed is 100%.

2. FIRST TIME QUALITY: The net quantity of parts that are acceptable at the end of a process,
divided by the original quantity started into the process, expressed as percentage; i.e., the
accepted parts yield rate. It does not give credit for the results of rework, scrap, etc.

How to calculate:

First Time Quality = Conforming Throughput

Total Throughput

Percentage Improvement = ( Improved State - Current State ) X 100

Current State
Note: This percentage can be greater than 100%.
 QUALITY WORKSHOP
DEFINITION OF QUALITY MEASURES - SHEET 2
3. PROCESS CAPABILITY: A measure of the capability of a process to produce a product
within specifications. The 6 sigma range of process’s inherent variation, for statistically stable
processes only. The measure is expresses as Ppk or Cpk. The performance index, Ppk, is
recommended for workshop use, given the time constraints of the workshop.
How to calculate:
Process Capability:
= =
USL-X X-LSL
Ppk = The performance index, typically defined as the minimum of or
^s
3 3^s

Cpk = The capability index for a stable process, typically defined as the minimum of
= =
(USL -X) (X-LSL)
or _
3
_
^ R/d 2
3^ R/d 2

Percentage Improvement = ( Improved State - Current State ) X 100

Current State

Note: This percentage can be greater than 100%.

Example: Current Index = 1.0

Improved Index = 1.3
.
% Change = .3 _. 1 X 100 = 30%

4. OVERALL QUALITY MEASUREMENT: A quality measure as viewed from the end

customer’s perspective. Typically based on the percentage of non-conforming products.
Examples are:
PPM Reduction
Relative Variation Reduction
Defects per Unit Reduction

How to calculate:

Percentage Reduction = ( Current State - Improved State )

X 100
Current State

Note: The maximum reduction allowed is 100%.