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Technorati : Lean, Marketing, Mistake-Proofing, Poka-Yoke, Six Sigma
Del.icio.us : Lean, Marketing, Mistake-Proofing, Poka-Yoke, Six Sigma

One of the important things you now must do is to consider the control device you will use to monitor the progress. In manufacturing we consider limit switches, stop/no go gauges. However, in service industries it can be much more difficult. In event planning though it could be something like an ineffective advertisement. You could build into it milestones that if it not achieved that certain positive or negative consequences occur.

Another example may be in developing advertisement copy; you may have certain acceptance criteria that are built into the process. It could be time sensitive, for example. You must remember even what seems like the best solution, if is uncontrollable will not lead to good results. You may want to consider another alternative and a result is that the perceived best action may change or become clearer as you improve. The method:

1. Start with the Root Cause of the mistake. Brainstorm ways to eliminate the mistake(Fishbone).
2. Note on each idea how you will handle the mistake: Don’t Accept, Don’t Make, Don’t Pass On.
3. Consider the cost and time of solving the problem
4. Place in matrix on Easy/Hard to do, Big/Low Payoff.
5. Review the controls to use.
6. Make your choice.
7. Proceed and monitor.

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Technorati : Control, Lean, Marketing, Mistake-Free, Poka-Yoke

The first tool I use may not be considered a tool at all, it is a mind set, This is NOT WHAT to DO. I keep this diagram around and embed it in most of things that are printed. It is very simple but the key to making a successful Poka-Yoke campaign.

The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.

Organize your mistakes(errors) and group them according to the Matrix. This will simplify the selection process on what mistake to tackle first.

I also have a list of Common Red Flag Conditions. These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first “WHY” in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing.

1. Frequent changes to a job
2. Complex processes
3. Lack of Standards
4. Lack of measurement systems
5. Lack of training
6. Long cycle times
7. Infrequent jobs
8. High output
9. Environmental conditions
10. Attitude ( Motivation)

The one tool that I left is the project sheet. We will start completing the components of this in the next blog and start creating a Poka-Yoke process in it’s entirety.

Technorati : Lean, Lean Six Sigma, Marketing, Poka-Yoke, Six Sigma

Mistakes happen for many reasons, but almost all can be prevented if we take the time to identify when and why they happen. Let’s take the time to define some terms before we start. A mini-project charter per say. Mistakes(errors) are any non-conformity(deviation) passed to the next stage or worse yet, does not meet the customers expectation. A defect is the result of these mistakes.

Many companies will wait for the final product to sample for mistakes and a certain percentage of rejects is acceptable. Other will do 100% inspection. But from a marketing standpoint, use direct mail as an example, how do you do that? The production of the direct mail piece itself may be measurable but the can you Poka-yoke the response? What response rate is acceptable or what you would call defective or broken? We will tackle this conversation in future posts but for now, let’s find out some suggestions on how to error proof a process.

The basic functions of Poka-yoke control are stop doing it(shutdown), control(make adjustments) and warning(red flags occurring). Maybe, more important, is the two terms, prediction and recognition. Prediction states that something is about to occur and recognition is something has occurred. The closer the source to the mistake that it is discovered the less costly is the problem. The whole point of Poka-yoke and as you instill the process detection, this will drive better feedback which generates the proper actions. This is a continuous process that once installed continues on and on.

Technorati : DMAIC, Lean, Poka-Yoke, marketing, six sigma

First, we must identify our processes that we use in developing for example an Advertising campaign, Trade Show or any type or of Event Launch. Each would require a different process flow diagram. In Six Sigma, this is the Define stage of the project. We will develop a team charter, process flow diagram and a few more items but our goal will be going after low hanging fruit. The goal is to simplify and mistake proof the process, keeping it simple is the key!

Secondly, we will examine areas that we may find errors in our process that would improve items such as delivery, taking on a job we may not qualify for and/or not have the proper equipment. In our post, we will break down these errors defining them further to see if we can control them.

Thirdly, we must get to the root of the problem to ensure that the improvement method we choose can be applied as a real solution, and not just a bandage. We typically use a fishbone diagram, to help prompt us to ask why at least five times. This will enable us to discover the root of the problem. Only then ask, how do we fix it and put the solution into practice Only at the time, do we determine how to create the basic improvements for our desired outcomes and create a roadmap to start and more importantly maintain the value stream created.

Review these E-books for more information:

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Technorati : DMAIC, Lean, Poka-Yoke, marketing, six sigma