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Quality Assurance by D. H. Stamatis

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453
Appendix III
Mistake Proong
Typical Mistake Proofing Development Process
Step 1: Defect
Describe the defect
Show the defect rate
Step 2: Location
Identify the location at which the defect is discovered or
made
Step 3: Operations
Detail the current standard procedure/elements of the opera-
tion where the defect is made
Make sure that one element is identied at a time
Step 4: Mistakes/deviations
Mistakes/deviations from standards where defects were
made
Step 5: Analysis
Analyze the cause for each mistake/deviation
Identify the red ag conditions
Step 6: Improvement ideas
Identify the ideas to eliminate or detect the mistake
Check mistake proong device required
Level 1: Eliminate cause of mistake at the source
Level 2: Detect mistake as it is being made
Level 3: Detect defect before it reaches the next operation
Step 7: Implement devices
Create a mistake-proong device
Mistake-proong improvement must consider the current and
future benets from a
Cost to install and any special comments, perspective
Time to install and date, perspective
454 Appendix III
Generic Mistake-Proofing Worksheet and an Example
A Generic Mistake-Proong Identication
Worksheet
Mistake-Proong Identication
Worksheet (Sample)
Plant: Plant Name
Area: Department
Date: Month/Day/Year
Plant: XYZ Engine plant
Area: Camshaft machining department
Date: 10/15/2014
I. Mistake-Proong System:
A brief description of what is used to mistake
proof the process. This may include a device,
an operational practice, or a xture.
I. Mistake-proong system: Proximity
switch on jaws of gantry robot.
II. Type
Is the mistake-proong approach prevention
or inspection/correction (refer to Key Card)?
II. Type: Inspection/correction.
III. Location
Where is the mistake-proong system
located in the plant?
III. Location: Camshaft machining—CAM
unloading station
IV. Description
A brief description of the process being
mistake proofed and how the mistake-
proong system prevents mistakes.
IV. Description: Camshafts entering the
machining process are unloaded by a
gantry robot. The coordinates that the
robot uses to locate the CAM are xed.
If a camshaft is not seated in the crate
correctly, or if the pallet is not in the
right place, the robot can secure the
CAM incorrectly and damage the CAM
or deliver it to the conveyor incorrectly.
V. Purpose
What mistake is being addressed and what
is the signicance of this mistake?
V. Purpose: The proximity switch releases
the gripper jaws before the CAM is
damaged. The mistake-proong device
protects the CAM if the CAM is seated
incorrectly in the pallet, or if the pallet
is located incorrectly under the robot.
VI. Condition
Is the mistake-proong system operational,
and how is it maintained?
VI. Condition: The proximity switch is in
working condition. The robot’s most
recent calibration and scheduled PM
were completed as indicated in the
maintenance log.
VII. Preventive Maintenance Schedule
What is the PM schedule for the mistake-
proong system?
The condition of the error-proong device and
PM schedule can be gathered from the plant
oor information system (PFIS) or something
similar to that. Maintenance personnel should
also keep a maintenance log in the area.
VII. Preventive maintenance: Weekly
calibration and monthly maintenance.
VIII. How the team recognized the mistake-
proong system
What indicator allowed the team to nd
the mistake-proong system?
VIII. How the team recognized the
mistake-proong system: Knew the
CAM seating and pallet location were
critical. Checked to see if there was a
mistake-proong device.

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