Practical, Feasible, and Cost-Effective Mistake-Proofing
Like any tool, sometimes even a mistake-proofing solution
itself may not be mistake-proofed and may be able to be overridden.
With sensory alert solutions, for the solution to work, the
operator must respond to the trigger or signal. If the solution (or
in the case of sensory alerts, the trigger) is not robust, it can be
ignored or disabled. And, in rare cases, be subject to malicious
To keep the trigger from being ignored:
- Make sure you
are mistake-proofing the root cause.
- Try to find a solution that
leads to mistake-prevention before settling for mistake-detection.
- Make the alert so obvious it is impossible to miss.
three classes of reasons why a device may be disabled.
- The device might be made of the wrong materials, perhaps a PM
schedule was never initiated, or maybe the calibration schedule is
- If the mistake-proofing solution is
difficult to use, if it requires frequent adjustments, or even if it
just gets in the way and conflicts with the standard machinery, it
may be susceptible to being disabled.
operators are not trained in the WHY as well as the HOW of a
mistake-proofing solution, it may not get used.
is when someone wants to make the process or product fail and
sabotages the mistake-proofing solution.