Driver Three: Error-Free Processing

There are two levels of achievement in error-free processing. Level I is achieved when you have initiated and successfully implemented at least one mistake-proofing initiative in all areas (departments) of the factory where production work is performed. Mistake-proofing is accomplished by using the established techniques of poka-yoke. Level II is achieved when you have applied mistake proofing to every key process in the plant, again using the established techniques of poka-yoke and most important, when you've established a means to continuously review, audit, and keep the key process list fully up to date. The following examines the purpose and intent of the distinct levels.

• Level I error-free processing. The purpose of level I is to start the process and to provide the learning and first hand experience required to become proficient at mistake proofing (poka-yoke). Here you need to apply at least some error-free processing throughout all the production areas in the factory. It is very important to have some plantwide exposure to the process of error-free processing before taking it to some ultimate application. Like the other three WFM drivers you need to have some successful applications in place early on in the process. Clearly, if done right, the benefits of this driver will be most obvious to all concerned.

• Level II error-free processing. The purpose of level II is to ensure that you have fully applied error-free processing to all critical or key processes in the plant. This starts by...