Workshop Description
People will make mistakes. However, letting mistakes become defects that cause Customer dissatisfaction or waste and rework is avoidable.
Process Risk Analysis & Mistake-Proofing is an effective method to prevent defects from occurring in an organization’s manufacturing, service, or administrative process.
Its objective is to design processes so that mistakes are impossible to make or, at the least, they are easy and early to detect and correct.
Workshop Benefits
The benefits of systematically mistake-proofing a manufacturing, service, or administrative process are:
- the systematic analysis of a manufacturing, service, or administrative process,
- the identification of critical and/or significant process characteristics,
- the development of an effective control plan,
- the identification of process deficiencies and development of an effective corrective action plan, and
- the systematic documentation of the rationale for changes.
Key Topics and Learning Points
The "Process Risk Analysis & Mistake-Proofing" workshop is very interactive with several hands-on small group exercises. The workshop covers our 10-Step Mistake-Proofing Process:
- Objectives and Benefits of Mistake-Proofing
- Process Mapping and Building Blocks Development
- Process Failure Mode and Effects Analysis - A Step-by-Step Approach
- The Sixteen Human Error Modes
- The Six Mistake-Proofing Principles
- Preventing Human Errors using Poka-Yoke Methods
- Developing an effective Process Control Plan
- Out-of-Control Action Plans
Workshop Requirements
None
Workshop Duration
This course is typically delivered as a one- or two-day workshop, depending on the possibility to integrate actual work processes into the workshop.
Who Should Attend
Process owners and employees throughout the organization involved in critical manufacturing or service processes that require mistake-proofing. The optimum number of participants is 3 to 4 teams of 4 to 5 team members each.
Project Support
Hands-on implementation support, if needed to transfer the learning and exercises to an existing manufacturing or service process, is of course available.
Kaizen Event Workshop
A Kaizen workshop is available for this course and in most cases consists of 1 to 2 days of planning and preparation followed by a two- to four-day Kaizen event. During the Kaizen event, the Mistake-Proofing methodology will be applied to a specific high-impact manufacturing, service, or administrative process. Typical Kaizen events have a payback time of less than 3 months.
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