Defects Vs. Errors

“Aim is for Zero Defects and

improved customer experience”

Anand Subramaniam

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“Women love us for our defects. If we have

enough of them, they will forgive us

everything, even our gigantic intellects.”

- Oscar Wilde

Defects Vs. Errors

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Defects Vs. Errors

The first step to “Source Inspection” is to

distinguish between Errors and Defects

“Defects” are the results

“Errors” are the causes of the results

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Zero Defects

The goal is to understand the concept and

practice of zero defects and how to

develop Poka-yoke to eliminate these

defects

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Poka-yoke

Poka-yoke – methods or devices to

improve product quality and ensure

consistent process results

Poka-yoke devices: Prompt feedback and action as soon as the

defect or error occurs

Perform 100% auto-inspection

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Defect Tracking

Defect Rates are tracked by: Quantity

Kind

Percent

With “Zero Defects” thinking, tracked at: The point at which defect is discovered

The point at which defect occurred

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Gemba Motto on Defects

Don’t get it.

Don’t make it.

Don’t send it 8

Errors Causes

Manufacturing Errors

Processing errors or

omissions

Assembly omissions or inclusion of the wrong part

Processing wrong work piece

Human Errors

Place blame and/or expect defects

Catch at final or sampling inspection

Make excuses

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Mistake Proofing Human Errors

Eliminate the possibility of the mistake

Find the root cause and eliminate

Ask why the process failed

Apply mistake-proofing device for 100% inspection

No defects generated 10

Mistake Proofing Machine Errors

Poka-yoke

A standard – a work method or procedure

A reliable method includes only those

elements which, when followed, cause a

predictable/desirable result, and when not

followed, result in a predictable defect

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Take Away..

Defects can be prevented

Error Proofing

Poka-yoke - to achieve zero defects

Make it impossible to produce defects

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“One of the great defects of English books

printed in the last century is the want of an

index.”

- Lafcadio Hearn

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Good Luck http://www.linkedin.com/in/anandsubramaniam