Abstract

Mistake proofing, also called poka-yoke, error proofing, or fool proofing, is a favorite method used by Six Sigma advocates for improving quality performance, and modern technology has enabled companies to integrate it into complex manufacturing operations with comparative ease. However, Six Sigma practitioners must be made aware of the value of using this method in generating the assembly operation defect space to enhance quality and eliminate defects. In automotive assembly processes, mistake proofing is frequently used to address customer concerns on specific issues. The find and fix cycle can take too long to identify the root causes of failures from returned products. In the example discussed, the goal was to move potential customer defects in the defect space to the containment space using mistake proofing methods. The improvement over the find and fix quality levels was due to using dedicated personnel to address all major observed defects systematically with mistake proofing.