Chapter 3Mistake Proofing

DOI: 10.4324/9781003185819-3

The causes of defects lie in worker errors, and defects are the results of neglecting those errors. It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.

Dr. Shigeo Shingo (1986)

Lean Goal Is Zero

Six Sigma tools are designed to measure, highlight, and eliminate defects with a focus on reducing errors to Six Sigma or 3.4 defects per million (see Table 3.1). But who wants to be one of the 3.4 people to get the defect? Many organizations use statistical process control (SPC). However, SPC will not ensure zero defects; since the defects are usually detected after they are made (historical data). SPC should be used as a preventive ...

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