Brainstorm Error Proofing Mechanism

• Make visible/obvious if incorrect part

  • Color code - match part to product
  • Visible at numerous operations and pack
  • Position of part as moves down line
  • Visual aid/picture posted with correct part present and highlighted

• Redefine process

  • Assemble early in process
  • Successive check
  • Rearrange multiple write-up to separate assembly of like parts

• Monitor part supply

  • Only supply parts needed for that model

• Sensors

  • Photoelectric eyes to detect, lock out until corrected
  • Limit switch to detect, lock out until corrected

• Modify/design fixture

  • Unable to assemble incorrect part

• Modify design

  • Eliminate part
  • Prevent assembly of incorrect part

Incorrect Parts- Thought Starters

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	The. Deming PDCA Cycle	QMS Implementation	FMEA Information	APQP Information
Auditing Information	8-D Problem Solving	Statistics	Error Proofing (Poka Yoke)	Brainstorming
Identifying Waste	Pull Systems	Lead Time Reduction	Planned Maintenance	Quick Setup
Discovering Change	Process Capability - Cp vs. Cpk	Histogram. Animation	Process Loop Animation	Taguchi Loss Function
		Fishbone / Cause and Effects Animation