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I8. Mistake Proofing
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hi welcome back in this section we will
discuss mystique goofy do you want
errors and mistakes recurring in your
processes I bet the answer is No
well mistake proofing is here to answer
that particular concern mistake proofing
or it's Japanese equivalent Pocoyo key
is the use of any device or method that
either makes it impossible for an error
to occur or makes the error immediately
obvious once it has occurred mistake
proofing aims to reduce the occurrences
of mistakes and errors that users in the
process commit mistake proofing can be
categorized into three subcategories the
highest level will be prevention second
that is detection and the least level is
containment once an error occurred in
the process what we want to do is to
contain it for it not to affect other
processes and for its impact to be
contained or minimized the higher form
will be detection now before the actual
defect or actual error or mistake will
be committed there is a way for you to
detect the likelihood of it happening or
detect whether it has been created
already or not giving you an idea of
stopping the process for you to minimize
the effect of that particular error or
defect now the ultimate goal as
mentioned is to prevent to eliminate the
possibility of the error or mistake to
be committed within the process so these
are the levels that we can play into
when we talk about mistake proofing what
is the best time to use mistake proofing
here are some best scenarios when we can
use mistake proofing when a process step
has been identified where human error
can cause mistakes or defects top or
especially in processes that rely on
workers attention skill or experience if
the process is fundamentally based on
the judgment of a human component then
there's a higher possibility of a
mistake according errors are most likely
to be committed by the human component
because of the poor process design that
has been embedded into our processes
next in a service process where the
customer can make an error which affects
the output let's say when you're filling
up a form in a bank or when you are
transacting in a government office so
their process is susceptible to errors
because there's a component of you
interacting with their process and if
the process design again is poor then
the likelihood of mistakes are high at
the handoff step in a process when
output or first service processes the
customer is transferred to another
worker when you say handoff this is the
activity where and you are endorsing or
you are giving your output to the next
process so mistakes is most likely to
happen on those particular gaps when a
minor error early in the process causes
major problems later in the process so
this is a classic example of a
particular error committed within a
process but does that mean deducted
early therefore creating more negative
impact to the whole process or series of
process steps inside your organization
and last when the consequences of an
error are expensive or dangerous when an
error let's say for example a medical
error or an industrial error or mistake
has the likelihood of being created then
it's the best scenario or chance for you
to implement a mistake proofing activity
it could mean a severe impact to the
employee's health and safety and could
mean a loss of life these are scenarios
for in mistake proofing is highly
recommended to be applied now in your
journey as a Lean Six Sigma practitioner
you have to understand that our
objective is that we want to prevent the
mistakes recurring so that we can reap
the gains of the improvements that we
have embedded into our processes coming
from the validated root causes now how
to use mistake proofing first you have
to rate a process map and review each
step for possible occurrence of errors
this is actually related to your natural
face wherein you have your process map
to identify potential causal step and we
are now identifying the possible
occurrence of error come
from those process steps number two for
each potential error identified the root
cause or source now this is in relation
to your analyze phase wherein we are
validating the potential root causes
using data for it to be valid if this is
valid then we will now put ways on how
to prevent this errors as given on
number three if it's not possible to
prevent it then think of ways on how to
detect the errors as early as possible
and number five implements the mistake
proofing action items as given in this
particular phase which is improve phase
now this is the general framework of how
we can identify mistakes before it can
happen and how can we implement those
mistake proofing action items moving
forward here are some examples of
mistake proofing activities or
strategies now look at your household
these are common examples that you can
see at their households or offices who
AOPA helps prevent mistakes while
manufacturing equipment for example this
is more of a design change when you see
your electric outlets or the cables that
are being used for projectors printers
and laptops there are specific cables
that are designed to fit on specific
slots of those equipments or appliances
this prevents putting the wrong cable
the wrong slab and we have examples that
we can see on the offices visual
management is also an example of music
proofing strategy using labels interval
files and your documents in the offices
and even on your personal household we
also have visual management applied to
input connections of TV or audio
appliances this color coding sockets
allows visual aid for workers and for US
consumers and one example mistake
proofing that has been done that I think
most of us can relate is that before the
way it runs up into an ATM is that you
have to transfer your card and then you
will do your transaction the money will
come out from the machine and then you
will have to pull out your card
the receipt problem is that there are
cases wherein the card is being left
into the machine now what the ATM
manufacturer did is to do sequence to
prevent the particular mistake if you
can notice the sequence is now card the
new Beltran sack then the card will come
out the money will come out and there is
it will come out last part of the transaction
transaction
now this eliminates the problem of cards
that are being left out in the ATMs
another set of examples are smoke
detectors in hotels offices the smoke
detector does not prevent the fire to
happen but it mitigates the risk of the
fire to have severe damage on the
particular facility by detecting it and
by putting mitigation actions like
triggering the water sprinklers the same
way a circuit breaker operates whenever
there is a short circuit then the
circuit breaker will cut the electric
operations at your household preventing
the possible severe damage of the
particular electric trip moving forward
what we want you to practice is that you
have to look for possible errors that
could happen in your process validate it
and put necessary mistake proofing
actions for the error not vertical
either it be a detection or prevention strategy
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