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Error proofing has many different names: Poka Yoke, Mistake Proofing, and Fail Safeing. They combine two methods of reducing defects in the workplace through error prevention and failure detection. These can be linked to many quality initiatives such as FMEA, Control Plans, and PTC. Error proofing techniques are also taken into account when designing a new process or upgrading an existing one.

There are many ways of preventing errors from occurring while manufacturing a product. Using prevention in the very beginning of the product design can help to ensure proper part manufacturing, especially when part complexity is a factor. Prevention in product design can also help reduce error proofing hardware implementation and costs in the future.

Prevention can also be designed into a machine. This is usually done to aid in ensuring part presence, orientation, or product type. Knowing these factors will prevent a product from being manufactured incorrectly and can help determine the cause of the error, leading to lower investigative time.

Identifying possible failures / errors that can occur in the field and their causes can also help in preventing the errors from taking place. Using the Failure Modes and Effects Analysis (FMEA) method to identify potential failures, causes, and effects, is the first step to knowing and preventing errors that may occur. If product design methods cannot be implemented, mechanical or electronic methods for prevention can be executed prior to starting production.

Detection of a failure is "after the fact" error proofing but extremely effective in protecting the customer nonetheless. Detecting a part while it is in station will help identify the problem right away without manufacturing more defective product.

Mechanical or electrical detections are usually implemented on a manufacturing line once an FMEA has identified the need. In many cases, detections are implemented to increase quality outcomes and reduce the cost associated with repairs.

Again, detections are most efficient when implemented within or shortly after the manufacturing of a product characteristic. Quick detection is the key to successfully implementing error proofing techniques.

DC fastening, vision systems, and mechanical on-line gauges are examples of some widely used methods of prevention and detection. Modern fastening techniques can prevent fasteners from being incorrectly torqued or seated as well as detect when an error has occurred.

Vision systems can also be implemented as both prevention and detection within a process. These systems can help ensure that the product you are installing is correct and detect that quality parts are being manufactured; they can be used in a number of applications.

Mechanical gauges such as specially machined depth tools, height bars, or actual quality gauges can help to ensure that the proper depth is being reached, no product beyond a certain height can be processed, or a specified quality outcome is being achieved.

There are also many simple process improvements that can be made to a manufacturing line that will have immediate benefits for mistake proofing the failure that is happening.

MEDA Limited has put many error proofing techniques into service industry wide. We can review the scope of your process and failure, help you identify those failures and causes, and suggest Poka Yoke methods and / or hardware to apply to your process to ensure lower reject cost and higher quality output.

For a broad overview of our services and how we can implement them, please see our Services and Solutions page.