If mistake proofing is really not cost effective and you've asked your operators for ideas then the real answer lies in CONTRACT REVIEW. Don't accept contracts that you can't profitably meet. Negotiate the acceptable ppm levels; too often Customers blindly apply very tight defect levels even tho the severity of the defect is minimal...
But you asked this same question in a different thread - there were some ideas on mistake proofing given in that thread. Are they also not possible in your situtaion?
But you asked this same question in a different thread - there were some ideas on mistake proofing given in that thread. Are they also not possible in your situtaion?