Error-Proofing in Manufacturing Process

Implementing controlled error-proofing in manufacturing is crucial for maintaining product quality by preventing and detecting errors. There are three primary methods for error prevention and detection:

Contact Method:

• Ensures error detection by verifying contact alignment, such as in error-proof socket designs.

Quantitative Method:

• Detects errors when a fixed quantity is not reached, like in part trace management for identifying omissions.

Sequential Method:

• Works in a fixed order to detect errors through interruptions, for example, using sealed compartments for assembling screws in a designated sequence.

Principles of Error-Proof Design:

1. Root Cause Principle: Eliminate error causes.
2. Insurance Principle: Require multiple actions for task completion.
3. Automatic Principle: Limit actions to prevent errors.
4. Conformity Principle: Verify actions for compliance.
5. Sequence Principle: Arrange tasks in a specific order to avoid mistakes.
6. Isolation Principle: Separate areas to protect critical components.
7. Layer Principle: Distinguish different tasks to prevent errors.
8. Duplication Principle: Use duplication for repetitive tasks.
9. Warning Principle: Display alerts for abnormal occurrences.
10. Mitigation Principle: Minimize damage from errors.

Implementation Strategies:

1. Mould and Fixture Error Prevention.
2. Machinery and Equipment Error Prevention.
3. Device and Marking Error-Proofing.
4. Operating Conditions Error-Proofing.
5. Design Structure Error-Proofing.

Levels of Error Prevention:

1. Preventing errors at the source to avoid defects.
2. Immediate error detection after occurrence to prevent defects.
3. Immediate detection of defects after occurrence to minimize damage.

Advocacy: Highlighting the importance of the first level of error prevention, which focuses on controlling errors at their source.