Mistake Proofing Basics-1, Guías, Proyectos, Investigaciones de Ingeniería Empresarial

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A Strategy for

Performance

Excellence

Table of Contents

• Session 1.0 Introduction…….……...……………………. Poka-Yoke ( Mistake Proofing)
• Session 2.0 Zero Defects & Costs………………………..
• Session 3.0 Waste Management ………………………..
• Session 4.0 Zero Defect Quality(ZDQ)………………….
• Session 5.0 Understanding Process Errors…………….
• Session 6.0 Four Elements of ZDQ……………………..
• Session 7.0 Seven Steps to Poka-Yoke………………….
• Session 8.0 Poka-Yoke Methods………………………..
• Session 9.0 Summary…………………………………….

Why is “Zero Defects” an

Important Concept?

Key Element in our capability

to implement Kaizen- Lean

Manufacturing Systems.

No need for “just in case” inventories

Allows company to make only what the

customer needs.

Why Kaizen

Time CPI Project Time CPI Time Savings Savings Savings Process Improvement Project Implemented Maintenance of Process Performance Kaizen

6 Sigma

• (^) Data Driven Methodology to Magnify Impact of

Process Improvement

• (^) Apply Control Techniques to Eliminate Erosion of

Improvements

• (^) Proceduralize/Standardize Improvements for

Improved Maintenance of Critical Process Parameters

Kaizen

• (^) Use Small Teams to Optimize Process Performance

by Implementing Incremental Change

• (^) Apply Intellectual Capital of Team Members Intimate

with Process

CPI Projects Emphasize

Control and Long Term

Maintenance

Kaizen Projects

Emphasize Incremental

Improvements

 Introduction

 Defects & Costs

 Waste Management

 Zero Defect Quality ( ZDQ)

 Understanding Process Errors

 Four Elements of ZDQ

 Seven Steps to Poka-Yoke Attainment

 Poka-Yoke Methods

 Summary

Why is “Zero Defects” an Important Concept?

Maintain Customer Satisfaction & Loyalty

Happy Customers mean more sales!

Costs of Defects?

Does it cost more to make processes better? NO

Making processes better leads to reduced

Rework

Scrap

Warranty costs

Inspection costs

1-10-100 Rule The 1-10-100 rule states that as a product or service moves through the production system, the cost of correcting An error multiplies by

Activity Cost Order entered correctly $ 1 Error detected in billing $ 10 Error detected by customer $ 100 Dissatisfied customer shares the experience with others the costs is $

Why is “Zero Defects” an

Important Concept?

Key Element in our capability

to eliminate waste.

Defects Misused resources

Inventories Untapped Resources

Motions

Delays

Processes

What is Waste?

Everything we do that costs something without adding value to the product Our objective > Value added = Maximum Non-Value Added = Minimum

Continuous Improvement

Is the continuous

elimination of waste

Elimination of Waste

The Method

Check and

measure

results

Identify

waste

Search for

causes

Implement

continuous

improvement

 Introduction

 Defects & Costs

 Waste Management

 Zero Defect Quality ( ZDQ)

 Understanding Process Errors

 Four Elements of ZDQ

 Seven Steps to Poka-Yoke Attainment

 Poka-Yoke Methods

 Summary

What is a Zero Defect Quality System (ZDQ)? A quality concept to manufacture ZERO defects & elimination of waste associated with defects!

“ZERO” is the goal!