Mistake Proofing: Achieving Perfection Through Simple Changes

Date: Thursday, November 3, 2011
Duration: 2 hours   See schedule below
Cost: $199
Instructor: Joanne Sauvey
Continuing education credits (CPE credits): Yes

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Have you ever wondered why it's so easy for improved processes to go back to where they started before the improvement efforts? Why, even if everybody follows the improvement recommendations, the process still produces defects? Why it's so hard to maintain the benefits in processes after projects are done? The answer to these questions is the effectiveness of implemented process controls.

In this interactive online training session, you'll learn about the most effective, yet simple process controls: poka yoke, or mistake proofing. Mistake-proof processes are intolerant to defects, either by preventing the occurrence of errors or detecting them when they happen. This is achieved through mistake-proofing devices -- simple process or product design changes that make defect prevention and correction infallible and, many times, effortless. When combined with Lean, Six Sigma or other process improvement methodologies, mistake proofing becomes a vital element in the solution of complicated issues.

From opportunity identification to solution development and evaluation, this course will take you through a stimulating, easy-to-follow four-step mistake proofing process. Both those new and familiar with mistake proofing will find this session useful since the objective will be the creation of mistake-proofing devices using innovation tools. Through the 21 principles for mistake proofing solutions, you'll ensure your team members have thought not only of traditional solutions but also of the unconventional, potential new ways to face opportunities.

This session will include lots of examples of implemented solutions and many shared experiences from the presenters. You'll see that whether preventing errors or detecting defects, mistake proofing devices change the way any process is executed, avoiding human errors and making it easier, better and safer.

Attendees of this two-hour session will learn how to:

• Understand mistake proofing and harness the benefits.
• Convert their team into a solid group of mistake-proofing developers.
• Identify opportunities to implement mistake-proofing solutions.
• Apply a four-step process to develop mistake-proofing devices.
• Use the 21 principles for mistake-proofing solutions.

Agenda topics:
The agenda for this online training course will follow the four-step mistake-proofing process:

Step 1: Identify opportunities for mistake proofing

• Review high-risk areas
• Understand the most common human mistakes
• Describe the defect
• Identify the location
• Investigate root cause

Step 2: Understand the job to be done

• Use the mistake proofing matrix based on TRIZ principles
• Describe the opportunity
• Define the job to be done

Step 3: Generate potential solutions

• Understand types of solutions
• Select the solution
• Prototyping/evaluation

Step 4: Implement the solution

• Create the prototype
• Test
• Evaluate the effectiveness of mistake proofing

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• Operations and quality leaders responsible for improvement efforts.
• Lean and Lean Six Sigma practitioners who lead projects and train team members on process controls.
• Process owners who are responsible for ensuring improvements are maintained.

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This IndustryWeek online course will provide 2 hours of instruction.

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Included with all registrations:

• Downloadable slides for note-taking
• 1 year access to an on-demand version of the course
• Continuing education credits
• BONUS:  A free set of downloadable mistake proofing templates (a $99 value!)

Cost:

• $199