The 10 most common types of errors: Error proofing can only affect the errors which potentially cause

defects not all errors cause defects! Here is a list of the 10 most common errors which EP is designed to correct or eliminate: 1.Processing omissions: Leaving out one or more process steps. 2. Processing errors: Process operation not performed according to the standard work procedures. 3. Error in setting up the workpiece: Using the wrong tooling or setting machine adjustments in correctly for the current product. 4. Missing parts: Not all parts included in the assembly, welding, or other processes. 5. Improper part/ item: Wrong part installed in assembly. 6. Processing wrong workpiece: Wrong part machined. 7. Operations errors: Carrying out an operation incorrectly; having the incorrect revision of a standard process or specification sheet. 8. Adjustment, measurement, dimension errors: Errors in machine adjustments, testing measurements or dimensions of a part coming in from a supplier. 9. Errors in equipment maintenance or repair: Defects caused by incorrect repairs or component replacement. 10. Error in preparation of blades, jigs, or tools: Damaged blades, poorly designed jigs, or wrong tools.

Identify the operation or process that needs to be mistake proofed (target areas where there are high numbers of errors or where even single errors are very costly). 2. Use the 5 Whys or cause and effect analysis to get to the root of the problem. 3. Decide whether to use a shut-out or attention type method (there may be technical or financial reasons why you have to go for the latter) to tackle the problem. 4. Decide whether a contact, constant number or sequence method is best (this will hinge on the nature and purpose of the activities). 5. Design an appropriate poka yoke. 6. Test it to see if it works (try to avoid large expense before you have completed this step - use mock ups or make-do's). 7. Once you have a working method then ensure you have the right tools/checklists/software, etc for it to work consistently and correctly. 8. Train everyone to use it. 9. After it has been in operation for a while (the time period will depend on the frequency of the activity) review performance to ensure errors have been eliminated. Take whatever steps are needed to improve on what you have done.

How it helps By taking steps to make it impossible to make mistakes, waste is prevented and processes run more smoothly. Enforces operational procedures or sequences . Ensures quality at the source instead of quality after the fact. Eliminates choices leading to incorrect actions

The goal of manufacturing is to produce value-added products in a timely manner, which is free of defects. Poke Yoke is applied in fundamental areas. The main objective of Poka Yoke is to achieve zero defects. It is used to create a system that prevents defects from occurring, and it used as a system to catch defects, which have just occurred and prevent them from continuing through the system. Poka-yoke helps people and processes work right the first time. Pokayoke refers to techniques that make it impossible to make mistakes. These techniques can drive defects out of products and processes and substantially improve quality and reliability. The basic concept of this is avoiding the problems by correcting the process.