Error correction
About error correction
Error proofing is a technique to eliminate errors. It is based on the premise that it is good to do something right the first time, is even better to make it impossible to get it wrong the first time. The idea is to make it impossible to make a mistake. You may also hear the term, Poka-Yoke or correction of an error correction applied error.
The objectives of this article are to provide participants with information so they can:
- Understand the difference between errors and defects;
- Understand how defects originate
- Recognize the elements of source inspection and its role in defect elimination;
- Identify key error testing devices;
- Show test error as a proactive tool, and;
- Show how error proofing is part of the Lean Six Sigma methodology.
Principles for the correction Error
Error correction is based on a profound respect for the intelligence of workers. It is a principle which seeks to take over repetitive tasks or actions thus releasing the time of a worker for creative and value-added activities. His goal is zero defects.
There are several examples of error tests in everyday life. Consider automatic sinks and toilets in public restrooms. They are designed to turn on and off without having to think about them. belts automatic safety function in the same way. All you have to do is sit in the car and turn the key and move a shoulder harness in place. Error test focuses to eliminate the source of errors.
Bugs vs. Flaws
The errors are not the same defects. defects cause errors. defects are often the result of errors.
Walk into any public restroom and it is likely they do not have toilets or sinks dump, with water running freely. In many cases, the hot water is turned off in the toilets to conserve energy costs to heat water. In these circumstances, what are the defects and what are the mistakes?
The defects are the dirty bathrooms and water current. These are the cases of failure in the process. They do not meet predetermined criteria that the public and management have established to the bathroom right. As such, must be corrected. If not corrected, it will cost management, both in terms of dollars and customers.
The hot water runs Uncontrolled involves a significant expenditure of fuel. filthy toilets to discourage the public to return to the company.
What is management do?
One solution is to leave the company. Many public places in the same line. Their bathrooms are closed to the public. A version The modified solution is to limit services to contain costs. This is the approach taken when you turn off the hot water management. The hope is that customers do not miss it. Another solution is to frequently inspect for defects and correct them when found. However, this solution is only effective if its cost is less than or equal to cost of default. Most times it's a stopgap measure that provides fewer defects, but at higher cost. Error testing offers a third solution.
The question is, does the error that causes the defect to minimize? Can it be eliminated?
The error in our example public lounge is human forgetfulness. People forget to use the computer. So we built in an automated solution that takes care of this for them. They can not make the mistake, the fault is removed.
There are five general reasons why errors occur:
- The procedures were incorrect or absent. They do not conform to the task, environment, equipment, materials, measurement, or labor resources.
- There is too much variation in the process
- There is too much variation in raw materials
- The measuring instruments are inaccurate
- Human error
The last item in the list, human error, can be subdivided into ten categories:
- Oblivion, No, or concentrate;
- Misunderstanding, or jump to conclusions without having all the information;
- Identification, or see the situation incorrectly (Maybe it's too far);
- Training, or lack thereof;
- Intentional errors in the human being passes ignore the rules;
- Inadvertent errors related to distraction or fatigue;
- Slow or delays in the trial;
- The lack of standards;
- Surprises when something does not go as planned, and;
- intentional errors such as sabotage.
This list should give some food for thought. There are many things that contribute to human error. These include adjustments, multitasking, tasks infrequent, the lack of standards, and the repetition that is too fast for the individual.
Such things can be controlled. In fact, much of the planning and expense is involved in the attempt to do so. However, errors still occur. A traditional approach to manufacturing and services is to think that they are unavoidable. People are human beings. All that varies, and can not plan for all contingencies. Traditionalists say that everything must be inspected to control inevitable default. (Remember that the defect is the result of an error.)
The Lean Six Sigma view, however, differs. Many errors can be eliminated, not all, of course, but many. If many can be eliminated, and many more can be reduced and if the focus of efforts is vital few rather than the many trivial then the need for the inspection may be reduced or eliminated. Inspection of defects does not capture all of them. Lean Six Sigma approach the user makes the inspector and controls that errors in the processes to ensure that the user is satisfied with their inspections. Inspection occurs on a Lean Six Sigma process, is an inspector for the error.
Source Inspection
The following table illustrates the traditional inspection process focuses on finding the defect. Here the inspector is at the end of the line and feeds back information to their different positions.
Error correction provides immediate feedback at each step, before the creation of a defect. detection is to find an error after it has occurred.
In fact, it can take action before errors occur. The immediate response and immediate proximity to the possibility of error allows better prediction and prevention.
Error correction at work
Closing: From both the prediction and detection. An example of a stop device is a camera that does not work when not enough light to take a picture. The meter predicts the image is not taken, on and off. Some clothes dryer off when it detects a situation of overheating.
Control: A control device can make errors impossible slopes. erroneous items can not be used in the process. When stations gas introduced unleaded petrol pump nozzle lead was designed to be too large to fit in a tank of unleaded gasoline, which prevents error. An orchard ensures that only large blocks show to their customers, from apples through a gauge. The apples that fall too small and are sent through of taking a discount.
Warning: A warning device predicts when something is about to go wrong. You can also sound immediately when something goes wrong. warning buzzers belt are devices used for prediction. Smoke detectors detects a situation dangerous.
Methods of Contact: Contact with some highlights errors. Electrical outlets are error-proof been to ensure the correct polarity. It is impossible to put a plug into an outlet incorrectly.
Fixed value methods: Errors are detected by counting. Many boxes will be delivered with four different labels warning of hazardous materials. When the labels were in separate rolls, Shipping errors often occurred. By placing the labels on a common roll and make for easy reference, the worker easily know when a label was lost.
Proposal Step Methods: Detection of errors by motion, or lack it. Seven different sized screws were inserted in the final assembly of a CD-ROM. Often, a screw would be forgotten. The seven different screws were placed in containers with photoelectric switches. When a screw is removed, the beam is broken. A party can not proceed to the next operation until the beam is divided into seven containers.
Begin to recognize the techniques and methods that apply to testing error is easy to see how the director has been implemented. The final horses are commonly applied to ensure that the machines are not working beyond its design capacity or that are operated safely. Guide pins are commonly used to ensure that templates and molds go together in the correct configuration. At the end of this module are eight challenges error tests. How can the problems be solved?
When you can not go wrong in the test
Some strategies can be employed to minimize errors, or make them easier to detect. Consider:
- The colors and code colors. Credit card receipts are almost always designed so that the client gets the yellow copy and the merchant receives the white copy.
- Use forms. Stop signs always octagonal.
- Auto-detection. Word processors have spell checkers. These reduce errors significantly.
- Make it easy to do well. Use checklists. Have effective ways of collecting data that follow the process. Design workflows less hand-offs.
5 steps to correct error
There are five steps for error correction:
1. Identify the problems. Mira customer returns, analysis of defective parts, and bug reports. Make a FMEA.
2. Prioritize problems. Look at the frequency of problem and cost. Identify wasted materials, rework time, detection time and cost of detection. Consider the costs of inspection.
3. Find the root cause. Scroll down until you truly understand the source of the error. Correct errors in source.
. Creating Solutions 4. Make it impossible to do evil. Conduct a cost-benefit analysis to see how long the investment in the solution will have to pay it. Be creative in generating solution.
5. Measure success. Errors were eliminated, and what is the impact?
There is no doubt that it offers several advantages when testing error is designed into the product. No formal training programs are required to apply or use the devices. Eliminates many of the inspection, and that frees operators from repetitive tasks that take away from your creativity and value-added activities. It is the result work free from defects. Provides an immediate action when problems arise.
Challenges error correction
Look, the following situations. What error testing methods or techniques that could consider the application?
- ATM customers complain they never know the correct way to insert your ATM card, and usually takes a couple of tries to do well.
- A local bottling company wants to ensure that all bottles are filled with exactly the right amount of soda.
- A large pharmaceutical company is trying to develop a way of ensuring that older people living alone take your prescription medicine at the right time and in the correct dose.
- A manufacturer of power tools home wants to ensure that customers bring eyes and hands before using your equipment.
- A consumer electronics company has had several complaints from customers recently that their instructions were disappeared from their product.
- Nine different tools needed to change a template and die. Often in the midst of change, operator set realizes a tool is not and has to stop looking for the tool.
- An easy to assemble furniture manufacturer has received several complaints about the holes are not taking advantage of all the screws. Because the furniture is made of hardwood, consumers have to drill their own holes.
- A contact lens solution manufacturer received complaints from retailers that some customers found empty boxes with their shipments. The company wants to ensure that gaps are no longer accepted being sent.
Steven Bonacorsi is a Senior Master Black Belt instructor and coach. Steven Bonacorsi has trained hundreds of Master Black Belts, Black Belts, Green Belts and project sponsors and leaders Executive Lean Six Sigma DMAIC and Design for Lean Six Sigma process improvement methodologies.
The AIT Group, Inc.
Steven Bonacorsi, Vice President
Lean Six Sigma Master Black Belt
3135 South Price Road, Suite 115
Chandler, AZ 85248-3549
Phone: + (1) 888.826.2484
E-mail: americas@theaitgroup.com
About the Author
Steven Bonacorsi is a Senior Master Black Belt instructor and coach. Steven Bonacorsi has trained hundreds of Master Black Belts, Black Belts, Green Belts, and Project Sponsors and Executive Leaders in Lean Six Sigma DMAIC and Design for Lean Six Sigma process improvement methodologies.
Bonacorsi Consulting, LLC.
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