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1. INTRODUCTION
- Why Mistake-Proofing - Defects Happen
- Quality Framework and Evolution
- Inspection to Detect Defects
- Inspection to Provide Information to Improve the Process
- Mistake-Proofing and Source Inspection to Eliminate Defects
- Shiego Shingo: Source Inspection, Zero Quality Control, and the Poka-Yoke System
- A Further Evolutionary Step - Mistake-Proofing By Design
- The Six Principles of Mistake Proofing - an Introduction
2. MISTAKE-PROOFING PRINCIPLES
- Hierarchy of Principles and Moving Upstream to Product & Process Design
- Principle of Elimination
- Role of Product Design - Design out Potential Defects
- Examples
- Principle of Replacement
- Replace Error-Prone Product Features/Items
- Replace Error-Prone Process Steps
- Examples
- Principle of Prevention
- Prevent Errors with Product Design - Guidelines & Techniques
- Prevent Errors with Process Design - Guidelines & Techniques
- Poke-Yoke Devices - Sensors, Counters & Other
- Examples
- Principle of Facilitation
- Product Design Techniques to Facilitate Error Avoidance
- Process Design Techniques to Facilitate Error Avoidance
- Visual Controls
- Examples
- Principle of Detection
- Defect Detection - Poke Yoke Devices & Self-Checking
- Examples
- Principle of Mitigation
3. POKA YOKE
- The Three Primary Poka Yoke Methods
- Contact
- Counting
- Motion-Sequence
- Types of Sensing Devices
- Poka Yoke Applications and Examples
- Poka Yoke in Automated vs. Manual Processes
4. MISTAKE-PROOFING AND DFM/A
- Principles of Design for Manufacturability/Assembly (DFM/A)
- Avoiding Complexity - Simplicity and Standardization
- Part Orientation and Handling to Facilitate Mistake-Proofing
- Insertion and Assembly
- Fastening
- Tolerances and Process Capability
- Impact of DFM/A on Quality and Defects
- DFM/A Examples
- Relationship of DFM/A Principles to Mistake-Proofing
- DFM/A and Mistake-Proofing Exercises
5. MISTAKE-PROOFING USE AND SERVICE
- Mistake-Proofing Customer Use
- Mistake-Proofing Customer Use Examples
- Mistake-Proofing Product Service
- Mistake-Proofing Service Examples
6. PROCESS FOR MISTAKE-PROOFING BY DESIGN
- Three Approaches to Mistake-Proofing
- Defect Analysis (Existing Products)
- Prioritizing Opportunities with Failure Modes and Effects Analysis
- Comprehensive Process Step Design
- Mistake-Proofing Taxonomy
- Understanding and Applying the Economics of Mistake-Proofing
- Examples of Mistake-Proofing with Your Products
- Discussion of Potential Opportunities with Your Products
7. SUMMARY
- Steps to Take to Implement a Mistake-Proofing Program
- Discussion and Questions
8. PRODUCT ANALYSIS OR FACTORY WALK-THROUGH
- Workshop Exercise to Apply Principles and Analysis to a Current Product
- Factory Walk-Through to Identify Mistake-Proofing Opportunities and Techniques
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