Ten Basic Rules of Fool-proofing

In production management, error-proofing measures (also known as "error-proofing technology") are a systematic management method that prevents and reduces the occurrence of errors in the production process by combining technology and management means. The following are specific implementation methods:

1. Technical means

Technical means mainly prevent the occurrence of errors through the design of automation, equipment and systems.

(1) Design of automated and intelligent equipment

• Automated equipment: Use automated equipment to replace manual operations to reduce the possibility of human errors. For example, use robots for assembly, testing and other operations.

• Intelligent equipment: The equipment has built-in sensors and control systems that can monitor the production process in real time and automatically detect and eliminate potential errors.

(2) Error-proofing design of products and processes

Add error-proofing mechanisms to product design and equipment design, for example:

• Shape error-proofing: Prevent incorrect assembly through shape design, such as matching the shape of plugs and sockets.

• Color error-proofing: Use colors to distinguish different components to avoid confusion.

• Size error-proofing: Prevent incorrect installation through size design, such as designing parts of different specifications into different sizes.

2. Management methods

Management methods mainly prevent errors by optimizing processes, strengthening training and establishing a quality management system.

(1) Process standardization

Develop detailed operating procedures and standards to ensure that each link has clear operating specifications to reduce errors caused by arbitrariness.

(2) Employee training

Regularly conduct skill training for employees to improve their operating skills and quality awareness. Through case analysis, simulation training and other methods, enhance employees' error prevention awareness so that they can actively identify and prevent errors.

3. Combination of technology and management

Technology and management methods need to be organically combined to effectively implement error prevention measures.

(1) Technology support management

• Data support decision-making: Collect and analyze data through technical means to provide support for management decisions.

• Automation assisted management: Use automated equipment and systems to reduce the complexity of management work and improve management efficiency.

(2) Management promotes technology application

• System guarantee technology application: Ensure the effective application of technology through management systems and technical specifications.

• Continuous improvement: Promote continuous improvement and innovation of technology through management means to continuously improve error prevention capabilities. Through the above methods, error-proofing measures can effectively prevent and reduce errors in the production process, improve production efficiency and product quality, and reduce costs and risks.

1. The fool-proofing method cannot solve all problems.

That is to say, there is no good fool-proofing solution for some current problems. In a sense, fool-proofing is not omnipotent.

2. The fool-proofing method is one of the error-proofing methods.

In fact, there is a certain difference between the fool-proofing method and the error-proofing method. The fool-proofing method mainly refers to the error-proofing method that does not rely on people. However, improving people's skills or awareness through training, job training, assessment and other means is undoubtedly an effective method of error-proofing.

Strictly speaking, the error-proofing method includes the fool-proofing method, and the fool-proofing method is only one of the error-proofing methods. Due to the obvious effect of the fool-proofing method, it is often respected.

3. The ten principles of fool-proofing have a certain order.

The ten principles are: ① root cutting principle, ② insurance principle, ③ automatic principle, ④ matching principle, ⑤ sequence principle, ⑥ replication principle, ⑦ layer principle, ⑧ isolation principle, ⑨ warning principle, ⑩ mitigation principle. The ten principles are the main basis for implementing the fool-proofing method, but the ten principles themselves have a certain order, and the general order is "① Try to eliminate the root cause so that errors cannot occur; ② Try to replace manual operations with automatic operations; ③ Simplify the means of operation to reduce the probability of errors; ④ Inform in time through alarms; ⑤ When errors are inevitable, try to mitigate their impact."

4. Fault-proofing sometimes does not completely eliminate errors, but only reduces the probability of errors.

Fool-proofing certainly prioritizes the pursuit of "root elimination", that is, eliminating the root cause of errors. But in fact, many fool-proofing methods only reduce the probability of errors. The value of reducing the probability of errors is still very prominent, such as the failure rate from 6% to 3%, its value is very obvious.

5. Root elimination in fool-proofing actually pursues "uniqueness" or "universality".

Fool-proofing prioritizes the pursuit of root elimination, because it eliminates the root cause of errors, making it impossible for errors to occur.

So, how to achieve root elimination? In fact, it is to strive to achieve "uniqueness" or "universality". The so-called uniqueness means that there is only one possibility of correctness. For example, the three holes of part A correspond to the three holes of part B one by one. If they are installed incorrectly, they cannot be installed at all. This is uniqueness. And universality means that no matter how you do it, it is right. No matter which end of bearing A is installed in the hole of part B, it can be installed. This is universality.

6. A fool-proofing device may implicitly match several fool-proofing principles.

For example, a fool-proofing device contains both automatic principles and warning principles, while another fool-proofing device is both a matching principle and also plays a root-breaking role.

7. Fool-proofing depends on technological progress.

With technological progress, problems that could not be solved in the past now have good or mature solutions. Technological progress is reflected in the increasing level of automatic operation, which in itself can avoid human errors.

8. Fool-proofing devices can also fail.

The fool-proofing device itself is used to prevent operational errors, but it can also fail. For example, the optical inspection device (CCD) may fail after working for a long time.

To prevent the failure of the fool-proofing device, on the one hand, the fool-proofing device must be verified when it is enabled, and on the other hand, the fool-proofing device in normal use should be verified for its effectiveness every day.

The specific approach is to list the list of fool-proofing devices and formulate the corresponding verification frequency. Generally, verification work is carried out before daily production to prevent large-scale defects.

9. The fool-proofing method implicitly conforms to the concept of "low-cost improvement".

This concept advocates that after mastering the fool-proofing method, by adding some settings and modifications, the existing equipment or operations have the function of fool-proofing, rather than relying entirely on the purchase of high-tech equipment.

10. Fool-proofing thinking is very important.

There are many cases where designers lack the basic thinking of fool-proofing, which leads to customer complaints.

On the other hand, even ordinary employees can use the knowledge and thinking of fool-proofing to better promote on-site improvement.