Human Error & Mistake Proofing: Simple Changes for Everyday Mistakes

Overview

To err is human. Because most processes involve people, and all people make mistakes, even the best laid process improvements can go awry.

The training begins with an introduction of a behaviorist model providing a framework to think about and understand specific behaviors that result in human errors. According to one prominent theory, human errors occur in primarily three modes: skill-based, rule-based and knowledge-based situations. The model provides a useful context for how to recognize the three situations when humans often make mistakes.

The discussion of human errors will continue with common failures behind each human failure mode and introduce methods for mitigating the behaviors resulting in the errors. The behaviorist models provide a solid foundation for numerous organizational situations, both transactional and manufacturing, to support the development of techniques that reduce the likelihood of everyday human error.

Building on the theory of human error, we’ll continue to explore effective, simple mistake-proofing controls and techniques for manufacturing, transactional and customer processes that make defect prevention and correction infallible and, many times, effortless. Mistake-proofing, or poka yoke, involves process or product design changes that either prevent the occurrence of errors or detect them when they happen. When combined with Lean, Six Sigma or other process improvement methodologies, mistake proofing becomes a vital element in the solution of complicated issues.

This course will take you through a seven-step mistake proofing method that will include the 21 principles for mistake-proofing solutions, innovative brainstorming techniques complemented by examples and shared experiences from the presenters. Both those new and familiar with mistake proofing will find this session useful since the objective will be the creation of mistake-proofing devices using several innovation tools. You will gain knowledge in both traditional and unconventional ways to change how any process is executed, avoiding human errors and making it easier, better and safer.

Attendees of this two-hour session will learn how to:

• Provide a foundational model to understand theories behind human error and the types of failures that often occur in specific situations.
• Recognize the common situations when humans make errors and techniques to mitigate them before they occur.
• Understand mistake proofing and harness the benefits.
• Convert teams into a solid group of mistake-proofing developers in transactional, manufacturing and customer-orientated environments.
• Identify opportunities to implement mistake-proofing solutions.
• Apply a seven-step process to develop mistake-proofing devices.
• Use the 21 principles and innovation techniques for mistake-proofing solutions.

Agenda topics:

• Current behaviorist models to understand and reduce human errors
• Mistake proofing definitions and benefits
• Types of mistake-proofing solutions
• Mistake proofing techniques for transactional, manufacturing and customer-related processes
• Brainstorming solutions, including Separation Principles and Resource Optimization
• How to select optimum solutions via the Solution Selection Matrix

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Who should attend

• Operations and quality leaders responsible for improvement efforts
• Lean and Lean Six Sigma practitioners who lead projects and train team members on process controls
• Process owners who are responsible for ensuring improvements are maintained

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Instructors

Joanne Sauvey is an experienced Lean Six Sigma practitioner and trainer who is credited with developing BMGI's online Green Belt and Black Belt curricula. In her capacity as an eInstructor, Sauvey trains and mentors practitioners across North America, New Zealand, Europe and Asia in a wide variety of industries, including healthcare, manufacturing, utilities, financial services and technology. Sauvey also manages the Master Black Belt development program at BMGI, working with practitioners to expand their mastery of Lean Six Sigma. She holds a Bachelor's in Industrial and Systems Engineering from Ohio University, and is a certified Lean Six Sigma Master Black Belt.
 

Kevin Kelleher brings more than 20 years of experience to his role as advisor to senior executives, directors and managers as they plan and implement strategic process improvements. In addition to training executives and practitioners in team dynamics, Lean and Six Sigma, he partners with organizations to develop their own training programs using blended learning models. Kelleher has a Master's in Public Health (Biostatistics) from the University of Massachusetts and a B.A. in Zoology from the University of Maine. He is a contributing author to several books, including Fourth Generation Management: The New Business Consciousness and The Innovator's Toolkit 50+ Techniques for Predictable and Sustainable Organic Growth. Kelleher is also a Lean Six Sigma Master Black Belt and a member of the American Society for Quality.
 

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