How to Detect & Prevent Mistakes in Manufacturing Processes
Summary
Set up a meeting including people like a customer representative, someone from product design, someone from manufacturing operations and ideally someone from quality. Identify what could happen and try to classify it into those categories of safety, critical fit form and function and visual defect. The next level down from that, if poka yoking isn’t really possible, is to put in some kind of visual alert and then immediately afterwards a verification. When that happens, the amount of re-work to strip that product right back, replace the components and then put it through the manufacturing process again is extremely costly. Then start tracking daily, weekly or monthly, in an Excel spreadsheet is fine, to make sure that the metric is going in the right direction.
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