from our weekly newsletter, The Visual Thinker

2016
Posted by & filed under Quality.

Mistake-Proofing Series Part 6 of 8. Read Parts: 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8

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This eight-part series was co-written by Drs. Hinckley and Galsworth, under Dr. Hinckley’s signature, based on the training system they jointly developed: The SMS Method for Perfect Quality.

Although simplifying products and processes can achieve remarkable reductions in mistakes and associated defects, this approach cannot completely eliminate mistakes or defects. We already explained why SPC is ineffective at controlling mistakes and the defects they cause—which is also why DMAIC is not the defect-control tool of choice although it is a powerful problem-solving method. The fact is, there is no method or combination of methods that can prevent all causes of mistakes that lead to defects. That is why true mistake-proofing (aka, poka-yoke) always uses devices to either prevent mistakes or prevent that defects caused by mistakes from entering the production stream. That is precisely why a true mistake-proofing process is part two of The SMS Method.

Why Most Training In Mistake-Proofing Fails

The traditional method of teaching mistake-proofing is based on sharing many examples. Unfortunately, the examples shared may not be useful for the audience, may not be remembered when needed, or participants may dismiss a useful example because it comes from an industry different than their own. Even after seeing many examples, individuals can still have difficulty developing mistake-proofing concepts. The SMS Method addresses this problem, head on.

How We Help You Develop Mistake-Proofing Solutions

The prime focus of SMS’s mistake-proofing technique is to make it easy for anyone to quickly create highly-effective and inexpensive devices that reduce or eliminate the errors that leads to defects. Central to this is SMS’s outcome template that allows you to define the type of defect you encountered within a larger logic. This template is married to a searchable array of relevant solutions. For example, solutions that prevent missing parts differ significantly from those that prevent putting parts in the wrong orientation. In other words, for defect challenges we narrow the search for a solution to highly relevant examples. My book, Make No Mistake (Productivity Press) has 200 searchable examples. Plus my free online resource has hundreds more: https://assuredquality/mobile. In combination with The SMS Method, these tools help you—help everyone—develop mistake-proofing solutions like experts and almost as quickly. Shown below are a few examples of mistake-proofing device.SMP Secrets chartPrint This Article Print This Article