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Management
Lean Six Sigma Operational - Delegate Workbook

Mistake Proofing Techniques

2

Learning Objectives
At the end of this section delegates will be able to:
• Explain the role of Mistake Proofing within Lean Six Sigma
• Recognise that defects can be eliminated (100% of the time) • Understand that Mistake Proofing should be focused on process steps that rely on operator vigilance and concentration • Recognise that simple, low cost devices can be the most effective solutions
• Use a simple process for implementing a Mistake Proofing system SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008

SSG06101ENUK - MP/Issue 1.1/ September 2008

1

©The British Standards Institution 2008

Lean Six Sigma Operational - Delegate Workbook

3

History of Error Proofing
• Dr Shigeo Shingo attributed with developing the methods
• Originally called Idiot Proofing but recognised that this label could offend workers so changed to Mistake Proofing (Poka
Yoke in Japanese)
• Literally translated
• Yokeru: to avoid
• Poka: inadvertent errors
• Target of Zero Defects and elimination of QC Inspection

SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008

4

Human Error
• Humans make mistakes (errors) because of……
- Forgetfulness

- Misunderstanding

- Lack of experience/skills

- Lack of concentration

- Laziness

- Lack of standards

- Rushing

- Taking short cuts

- Malicious intent (deliberate action)

• Errors (can) lead to defects
• Defects are not inevitable and can be eliminated by the use of simple, low cost methods – zero defects
• Mistake Proofing should take over repetitive tasks that depend on vigilance or memory

SSG06101ENUK – Delegate Slides/Issue 1.1/ September 2008

SSG06101ENUK - MP/Issue 1.1/ September 2008

2

©The British Standards Institution 2008

Lean Six Sigma Operational - Delegate Workbook

5

Types of Error
Four main types of error:
Processing
1.

Omitted Processing -

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