Error proofing IATF16949:2016
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The document outlines error proofing in the context of IATF 16949, defining error as unintentional mistakes in manufacturing and emphasizing the importance of a structured approach to eliminate these errors. It details the requirements for documentation and methodologies, including process risk analysis and testing plans, while advocating for techniques such as Design for Manufacturing (DFM) and Poka-Yoke systems to prevent defects. The text presents a process for identifying and addressing potential errors, culminating in documented examples of preventive and detection measures.
Error proofing IATF16949:2016
- 1. Error Proofing IATF-16949 By Bilal Ashar
- 2. Outlines What is Error? What is Error Proofing? What does standard requires? Basic Philosophy How do we error Proof? Techniques to error proof. Documented Examples
- 3. What is meaning of ERROR? ERROR Errors are inadvertent, unintentional, accidental mistakes made by people because of the human sensitivity designed into our products, which result in those “once in a while” defects that we always find difficult to control. Inadvertent errors are not only possible, but inevitable, and they happen regularly.
- 4. What is Error Proofing? Error Proofing Error-proofing represents a structured approach to ensuring the quality of products throughout the entire manufacturing process, by eliminating the possibility of error. Note The focus of error-proofing is not on identifying and counting defects rather, it is on the elimination of their cause: one or more errors that occur somewhere in the production process.
- 5. What does standard require ? Error Proofing is a part of improvement Standard Requires: 1. Documented Process for error-proofing methodology. 2. Methodology should be documented in the process risk analysis, such as PFMEA (Process Failure Mode Effect Analysis) 3. The test frequency should be documented in the Control Plan. 4. Documented process includes testing of Error-Proofing devices for failure or fake failure. 5. Maintain Records. 6. Challenge Parts should be identified controlled verified and calibrated, Where feasible. 7. Error Proofing device shall have Reaction plan.
- 6. Philosophy Points to consider Recognize that people, machines, and processes make errors Respect the intelligence of workers by removing the judgment from repetitive tasks or actions where errors are likely to occur. Refuse to accept “human error” as an excuse for root cause of a problem. Recognize that creating the “zero defects” standard and reaching the zero defects objective is everyone’s responsibility
- 7. Process for Error-Proofing Identify the Error Identify the appropriate mistake proofing method Development of mistake proofing method Approval Implementation and documentary evidence Evaluate its effectiveness
- 8. How do we Error Proof? Awareness Detection Prevention
- 9. Techniques for Error Proof? 2 Main Techniques Designing For Manufacturing (DFM) Poka Yoke
- 10. DFM? Design for Manufacturing (DFM) is the process of designing parts, components, products or process for ease of manufacturing with an end goal of making a better product at a lower cost. Or Integration of process design and product planning to design a product that is easily and economically manufactured. Five Examined Principles during DFM Process Design Material Environment Compliance/ Testing
- 11. Benefits of DFM
- 12. Poka-Yoke? Poka- Yoke is a Japanese term that means "mistake-proofing" or "inadvertent error prevention". A poka-yoke is any mechanism in any process that helps an equipment operator avoid (yoke) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
- 13. Examples?
- 14. Examples?
- 15. Benefits?
- 16. Poka yoke?
- 23. PFMEA and Control Plan Example(Prevention) Process Function Require ment Potential Failure Mode Potentia l Effect of Failure Sev. (S) Class. Potentia l Cause of Failure Occ . (O) Current Process Control Det. (D) R P N (SxOxD ) Recom mende d Action Respo nsibilit y Target Compl etion Date Action Results Preventi on Detecti on Action Taken & Compl etion Date S O D RPN 1 ManualBu shing Insertion of terminals Reverse d bushing NG Product 7 P Similarit y of Terminal s 4 N/A Visual 5 140 Manual Insertio n Jig J- 12 Mr. Sajid (Desing ing) xxx xxx xx xx xx xx Part/ Process Number Process Name/ Operation Descripti on Machine, Device, Jigs, Tools for Mfg. Characteristics Special charact eristics Class Methods Person In Charge Reaction Plan No. Product Process Product/Pro cess Specificatio n/Tolerance Evaluati on Measur ement Techniq ue Sample Control Method PD QC Size Freq. 1 Manual Bushing Manual Insertion Jig J-12 1 Diameters +ve STD 18 ± 0.5 % Gauges/I nside caliper 100% 100% xxx 1. Check the Terminals Lot. 2. Inspection of Jig by Quality Control. -ve STD 16
- 24. PFMEA and Control Plan Example(Detection) Process Function Require ment Potential Failure Mode Potentia l Effect of Failure Sev. (S) Class. Potentia l Cause of Failure Occ . (O) Current Process Control Det. (D) R P N (SxOxD ) Recom mende d Action Respo nsibilit y Target Compl etion Date Action Results Preventi on Detecti on Action Taken & Compl etion Date S O D RPN 1 Radiator Cooling For normal Engine condition s Overheat ing Engine Cease 7 C Late indicatio n 4 N/A Car Led Light detectio n 5 140 Digital Temp Device xxx xxx xxx xx xx xx xx Part/ Process Number Process Name/ Operation Descripti on Machine, Device, Jigs, Tools for Mfg. Characteristics Special charact eristics Class Methods Person In Charge Reaction Plan No. Product Process Product/Pro cess Specificatio n/Tolerance Evaluati on Measur ement Techniq ue Sample Control Method PD QC Size Freq. 1 Radiator Cooling Digital Temp Device 1 Temp 80 Celcius ± 0.5 % External Master thermoco uple 100% 100% xxx Replace the new device
- 25. Golden Nugget?