Mistake Proofing

If your goal is 100% zero defects, here is the book for you — a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole. The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants. The book: Organizes examples according to the broad issue or problem they address. Pinpoints how poka-yoke applies to specific devices, parts and products, categories of improvement methods, and processes. Provides sample improvement forms for you to sketch out your own ideas. Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)

With C. Martin Hinckley's new book Make No Mistake! An Outcome Based Approach to Mistake-Proofing, that vision can become a reality. If you work for a company that emphasizes traditional quality control methods, it's unlikely that you've seen defects eliminated despite your substantial efforts. Make No Mistake! clarifies the reasons why such traditional methods fail and shows how world-class quality can be achieved at a minimal cost through mistake-proofing — the practice of controlling virtually every source of potential errors. As the author states, "The great value of mistake-proofing is that, independent of the cause, psychological factor, production stage, or potential consequences, it blocks or warns about an undesired outcome at a point in the process when the consequences can be minimized." Truly the first of its kind, Make No Mistake! is a compendium of the best methods for reducing complexity, variation, confusion and the other root causes of defects — but the centerpiece of this powerful mistake-proofing tool is an outcome-based classification system that focuses on preventing rather than detecting defects. Even more importantly, Hinckley's mistake-proofing documentation forms will help you adapt this methodology to your own defect prevention efforts. Make No Mistake! is an amazing compilation of mistake-proofing tools that is encyclopedic in scope. Because mistake-proofing is a skill that improves through familiarity with previous solutions, Hinckley's new classification systems is the key to rapidly finding outstanding solutions to current problems on the shop floor. Make No Mistake! is one book that will be invaluable in your company's quest for quality. Make No Mistake! includes: Over 200 mistake-proofing examples from varied industries Easy-to-use mistake-proofing documentation forms you can use on the job Introduction to principles of mistake-proofing and design for assembly A quick, step-by-step methodology for developing superior mistake-proofing concepts Listing of select suppliers of mistake-proofing devices

" ... a step-by-step process that can be used to help create a very efficient error-free organization that will be able to compete with the best of companies"--Page 7.

The principles of mistake proofing, long used to eliminate errors and defects across a range of industries, are now being applied in healthcare organizations around the world to help ensure patient safety, improve services, and eliminate waste.Mistake Proofing for Lean Healthcare is based on the definitive mistake-proofing philosophy and system developed by Shigeo Shingo. This reader-friendly book introduces the main concepts and benefits of mistake proofing in healthcare and highlights common reasons that errors and defects occur. It also explains how to catch errors before they become defects, using the concept of source inspection, so you can ensure quality before a process is performed instead of afterward. When systematically used, the mistake-proofing approach explained in this book will help you:Create safer, more reliable, and more effective healthcare services for both patients and staffEstablish a culture in which mistakes and the conditions that cause them are readily surfaced so they can be correctedLay the foundation for processes that flow smoothly, without disruptionEliminate rework, waste, and the need for extra resources and suppliesPresenting real-world healthcare examples, the book shows different types of mistake-proofing devices and methods (poka-yoke) that provide feedback quickly and automatically to prevent errors and defects.The book is part of the Lean Healthcare Series and is designed for individual or group learning. Each chapter includes reflection questions to facilitate understanding and stimulate discussion and action.

A POWERFUL GUIDE to help you establish a culture of defect prevention by idea creation and team engagement. It shows how the habit of Mistake Proofing can be inculcated in to the DNA of the organisation. Drawing upon several years of research and hands on experience at various companies. Filled with more than 100 explicit EXAMPLES collected from diverse companies and day to day life, organised into a coherent framework of practical concepts that can be applied by managers both at Manufacturing and Service environment. ‘MISTAKE PROOFING SIMPLIFIED’ provides a master blueprint for a structured deployment and tips for sustenance of the program in a very simple yet effective manner. The book will help you understand the concept and develop your own strategy for step by step mechanism for a system towards ZERO DEFECT PROCESS.

For leaders who want the best for and from their employees Leadership and management is not easy. Most in those positions end up relying on their native intelligence, what worked before, shooting from the hip and what others suggest. In an engaging story of a group of leaders in a series of workshops, Mistake-Proofing Leadership teaches the reader proven tools to form teams, solve problems, promote change and a host of other important business activities. Learn what to do, when to do it, how to do it and avoid doing it poorly. Join a collaborative leadership workshop with eight others. Enjoy discovering new ways of leading, including mistake-proofing your mistake-proofing.

A combination of source inspection and mistake-proofing devices is the only method to get you to zero defects. Shigeo Shingo shows you how this proven system for reducing errors turns out the highest quality products in the shortest period of time. Shingo provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement. He also discusses inspection systems, quality control circles, and the function of management with regard to inspection.

This book illustrates how the strategic placement of 'error-proofing' devices, which is refered in this book as Success Every Time (SET), drives up industries' profits and throughput. It highlights the deficiencies of Failure Mode Effects Analysis (FMEA) and compares the strategy to the SET.