human error prevention ppt w201 part mix up
DESCRIPTION
Presentation on human error & preventionTRANSCRIPT
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Problem Definition: Part Mixup
Supplier Name : Sigma Vibracoustic V. Code : Location: Mohali
M&M SQA Managers Name : M&M SQA Officers Name:
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Problem Definition
Brief description of Problem
What : Parts Got Mix up
When: Internal During Packaging/Pre Despatch Inspection
Who: Inspector
Where: At Supplier End
Why: Due to operator negligiency
How: Problem noticed during pre despatch inspection/2 part
reported
Part Name : Bush Toe Bar Frame Model : W201
Part got mixed up
during packaging
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Guideline for 5W 1H ( For Reference Only )
Brief description of Problem
It should include details of what, where, when, present level and target .
What:What is troubling to the customer/organization, What is theissue? It can include which part/product/family/process as appropriate.
Where: Where problem is produced? Where it is detected? Whichlocation on the part (geographically or within the company) asappropriate.
When:When problem was first observed?
Who : Who has reported the Problem / Who is suffering?
Why:Why the Problem occurred?
How: How the Problem get noticed / How many Parts reported?Specify Current level based on the average data of last 4 to 6 months.
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Human Error PreventionPart Name Bush Toe Bar Frame
Part Number - 0402BA3000N
Model : W201
Process Stage : Packaging
Part got Mixed Up during packaging
because of same profile parts it was not
easy to detect the parts visually
FMEA Detection level Before : 7
Team members
1. Team leader : Mr. Parmod Makhija
2. Member 1 : Mr. Manil gogia
3. Member 2 : Mr. Jetesh Devgun
4. Stage Operator(Must) : Mr. Ram Bali
BEFORE :
Avg( PPMeq):
Training Date : Project Start Date : Project Completion Date :
Profile gauge for part inspection
During packaging
Inspection of part with
profile gauge
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Analysis of the Problem :Why Problem is Generated
Part Mix Up
Negligiency of operator
Lack of training
Inspection method not capable enough(only visual check during packaging)
WHY
Key Word :
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Human Error Prevention Check Sheet# Principles Question to be asked to the process Solution E C I SPN
1 Can we eliminate the error-prone process?Yes, by means of profile gauge for parts we can avoid mixup during
packaging2 3 2 12
2 Can we eliminate harmful objects? No such harmful object identified 1 1 1 1
3 Can we automate the process? No automation is there because of process & cost constraint 3 1 1 3
4Can we provide supporting tools like
checklists/gages/samples?Profile gauge provided 3 3 2 18
5Can we simplify changes/differences in the operations?
(standardization, code matching, etc)packaging specification available 2 3 2 12
6Can we distinct changes/differences in t he operations?
(color coding, unique shape, etc.)All processes have there own specific number 3 3 3 27
7 Can We adjust the properties of the operations which suitshuman beings?
All processes have established by considering HSE requirements 3 3 2 18
8Can we record the motion of the earlier operation and verify
it before starting the next operationYes, oiling done can be verified visually 3 3 2 18
9Can we restrict the motion in such way that it will notice
the abnormality?Yes, profile gauge can check the other profile part if any mixup is there 3 3 3 27
10
Can we verify the results before starting the next operation
?
(sensing shape/state/quality of work)
profile can be checked by means of profile gauge 2 3 2 12
11Can we make function parellel (Redundant)?(Additional
Control)Profile gauge can be implemented for other W201 parts also 3 2 2 12
12Can we incorporate some shock absorbing
materail/equipment?(Like Fuse)PPE's available 3 3 3 27
13Can we make unsafe conditions more safer so as to not to
produce the defects?(Protection)
Training can be provided to operators & inspectors for use of profile
gauge while packaging3 2 2 12
Mitigation
Facilitatation
Detection
Replacement
Elimination
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Improvement Photograph
BEFORE AFTER
Solution Implemented:
100% Visual Inspection
Inspection with profile gauge
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Sustenance Plan
S.N. Activity Resp Frequency Remarks
1
Through Process
Audits & Product
Audits
QA/Prod
A per
process/pro
duct audit
plan
Horizontal Deployment
S.N. Activity Resp Target Date Status
1 All W201 Bushes Prod/QA In process Open
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Movie - NA
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Result ( Improvement in RPN)
PFMEA Details Before After Actions taken
Severity Rating(S) 5 5
Occurance
Rating(O)
3 3
Detection Rating(D) 7 6 Profile gauge provided in process
during packaging
RPN(S x O X D) 105 90
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Result
4
8
10 0 0
0
123456789
10
Jan Feb Mar Apr May Jun Jul
Quantity
Trend Chart : PPMeq, R/1000, InternalRejection
Kaizen
Implemented
1stTime Problem Reported on : DD\MM\YY Solution Implemented on : DD\MM\YY
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Thanks
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Back up Documents - MUST
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MISQ ( Mahindra Inspection Standard for
Quality)Refer guideline if you are not aware
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Control Plan, PFMEA, PFC,SOP ( Ifchanged)