We can have four different effects from mistake-proofing.
They are forced control, shutdown, warning, and, sensory alert.
Any of the effects can have a prevention or detection outcome.
4 effects coupled with 2 outcomes yield 8 different potential types
The 8 types of solutions have different levels of
The first choice, whenever possible, is to
prevent the mistake from being made using a mistake-proofing
solution with a forced-control effect.
The second choice depends
on the situation:
If the cost of shutting down the line isnít too
great, then use a shutdown-prevention mistake-proofing solution to
prevent the mistake from occurring.
If however, it is more
expensive to shut down the process than to detect a mistake and
prevent it from getting out to the customer, then try a forced
The third choice would usually be a
Warning and sensory alert effects are
The distinction between an automatic trigger (for
forced control and shutdown) and an operator dependent trigger (for
warning and sensory alert) makes solutions with forced control and
shutdown effects more powerful.
Mistake-proofing solutions can be assigned a relative power
rating based on the effect used.
This table provides a visual
representation of the relative power of the four types of
The trigger (for initiating the
solution) is a major differentiator.
Forced control and shutdown
effects both have automatic triggers.
Warning and sensory alert
effects have triggers that depend on the operator to notice and
respond to them.