Comments on: An Error Proofing Challenge http://www.leanblog.org/2007/08/error-proofing-challenge/ Mark Graban's leanblog.org - Lean Healthcare, Lean Thinking, Lean Manufacturing, Toyota Production System Thu, 09 Feb 2012 15:26:57 +0000 hourly 1 http://wordpress.org/?v=3.3.1 By: triticale http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2552 triticale Sun, 09 Sep 2007 19:15:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2552 If there are a fixed set of individuals disregarding the instruction not to double-stack, send out an occasional "training" pallet configured to spectacularly self-destruct if double stacked, preferably in a manner which requires calling for assistance to clean up. If there are a fixed set of individuals disregarding the instruction not to double-stack, send out an occasional “training” pallet configured to spectacularly self-destruct if double stacked, preferably in a manner which requires calling for assistance to clean up.

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]]> By: Graham_C http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2506 Graham_C Sat, 25 Aug 2007 11:32:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2506 I would go back to the point a couple of people have made here. If your pallet is at risk from the transport method, either change your transport method (direct courier, v.expensive), change the packaging so that others can't stack on top (may have your shipment rejected by courier), or change your packaging so that it CAN be double stacked and handled by anyone. I would go back to the point a couple of people have made here. If your pallet is at risk from the transport method, either change your transport method (direct courier, v.expensive), change the packaging so that others can’t stack on top (may have your shipment rejected by courier), or change your packaging so that it CAN be double stacked and handled by anyone.

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]]> By: dwr @ MSGS http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2461 dwr @ MSGS Fri, 17 Aug 2007 12:08:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2461 First Anon is back...<br/>Mike, with your permission.<br/>Colleagues...Lean is about Value Streams thinking not individual problem solves or solvers. We need to assess the value stream before we design solutions...even error proofing. Why? Because when you change anything, you change everything.<br/>This is an interesting topic, so why not work it together. Let's SEE the current state through a series of entries here and then decide an appropriate Waste reducing solution.<br/>I will start by listing some assumptions.<br/>Assumumptions: <br/>This shipping qty is on takt for current customer/supplier relations.<br/>Flow is regular and repeating to a well defined but growing North American market.<br/>Total packaging costs are 1.0% of the piece cost.<br/>Damage/shrinkage is currently @ 2% of piece cost.<br/>Customer satisfaction is 90%. Dissatisfaction with handling the damage and getting credited for it and getting replaced/reimbursed accounts for all 10% dissatisfaction.<br/>The label was introduced 1 yr ago when damage was @ 3% of piece cost and cust sat was @ 85%.<br/>The customer is looking at other suppliers due to the damage trouble.<br/>The label means don't put anything on top of me.<br/>The material flows through break/bulk (cross docking) freight system.<br/>Now, let's discover. What else do we need to know about this scenario? First Anon is back…
Mike, with your permission.
Colleagues…Lean is about Value Streams thinking not individual problem solves or solvers. We need to assess the value stream before we design solutions…even error proofing. Why? Because when you change anything, you change everything.
This is an interesting topic, so why not work it together. Let’s SEE the current state through a series of entries here and then decide an appropriate Waste reducing solution.
I will start by listing some assumptions.
Assumumptions:
This shipping qty is on takt for current customer/supplier relations.
Flow is regular and repeating to a well defined but growing North American market.
Total packaging costs are 1.0% of the piece cost.
Damage/shrinkage is currently @ 2% of piece cost.
Customer satisfaction is 90%. Dissatisfaction with handling the damage and getting credited for it and getting replaced/reimbursed accounts for all 10% dissatisfaction.
The label was introduced 1 yr ago when damage was @ 3% of piece cost and cust sat was @ 85%.
The customer is looking at other suppliers due to the damage trouble.
The label means don’t put anything on top of me.
The material flows through break/bulk (cross docking) freight system.
Now, let’s discover. What else do we need to know about this scenario?

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]]> By: Dave http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2459 Dave Fri, 17 Aug 2007 05:14:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2459 Yes, that article on WSJ was great. Glad to know there's a place for me to work. <br/><br/>I like these puzzles that you put up. Keep them coming. Yes, that article on WSJ was great. Glad to know there’s a place for me to work.

I like these puzzles that you put up. Keep them coming.

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]]> By: Bob Yokl http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2454 Bob Yokl Fri, 17 Aug 2007 00:24:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2454 I am still curious though, was this through a distributor or the manufacturer. Hospira has direct and through distributors. I am still curious though, was this through a distributor or the manufacturer. Hospira has direct and through distributors.

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]]> By: Mark Graban http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2453 Mark Graban Fri, 17 Aug 2007 00:16:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2453 Bob, it could be a waste of time. This isn't something I am actively working on, it was just a question (and an attempt to illustrate how signs aren't effective error proofing).<br/><br/>If it's a waste of time, then why the pink sheet with the warning? Bob, it could be a waste of time. This isn’t something I am actively working on, it was just a question (and an attempt to illustrate how signs aren’t effective error proofing).

If it’s a waste of time, then why the pink sheet with the warning?

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]]> By: Bob http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2452 Bob Fri, 17 Aug 2007 00:12:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2452 What is the occurance percentage that Hospira or the hospital or the distributor of the IV products have with getting damaged or crushed? <br/><br/>If this is for a hospital's operation I think you are wasting your time on this equation. This will be broken down and sent to their storeroom or pharmacy (if refrig. needed). What is the occurance percentage that Hospira or the hospital or the distributor of the IV products have with getting damaged or crushed?

If this is for a hospital’s operation I think you are wasting your time on this equation. This will be broken down and sent to their storeroom or pharmacy (if refrig. needed).

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]]> By: Mark Graban http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2451 Mark Graban Thu, 16 Aug 2007 23:55:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2451 Thanks for the tip on the walgreens article, will check it out! <a HREF="http://online.wsj.com/article/SB118601925584985666.html" REL="nofollow">Link for the WSJ Subscribers</a> Thanks for the tip on the walgreens article, will check it out! Link for the WSJ Subscribers

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]]> By: Barry http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2447 Barry Thu, 16 Aug 2007 20:19:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2447 How about placing bubble wrap on top of the palette? The sound of placing another on top should be just enough to prevent it from happening again.<br/><br/>As far as breaking the shrink wrap, that sound like a problem with the supply distribution system. How about placing bubble wrap on top of the palette? The sound of placing another on top should be just enough to prevent it from happening again.

As far as breaking the shrink wrap, that sound like a problem with the supply distribution system.

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]]> By: Anonymous http://www.leanblog.org/2007/08/error-proofing-challenge/#comment-2445 Anonymous Thu, 16 Aug 2007 14:33:00 +0000 http://leanblog.bigbigdesign.net/2007/08/an-error-proofing-challenge/#comment-2445 Mark,<br/><br/>On the subject of containerizing goods, you might consider blogging about a recent WSJ article about Walgreen's commitment to hiring disabled workers at a regional warehouse. The article explains how they were able to error proof the workstations and improve their training to the point that they could hire folks with significant disabilities that would otherwise be thought to be unemployable.<br/><br/>It's a story about applying lean concepts to help solve a big societal problem, and make a profit at the same time. Kinda made my heart go pitter-patter, and opened my eyes to the possibilities for lean to help save the world. Makes me want to quit making junk people don't need, and instead apply my skills on something that solves a real problem.<br/><br/>The article is called "Erasing 'Un' from 'Unemployable'", Thursday Aug 2 WSJ Marketplace section. The photos show some of their workstation, which look very well done (highly visual, seemingly ergonomic). Mark,

On the subject of containerizing goods, you might consider blogging about a recent WSJ article about Walgreen’s commitment to hiring disabled workers at a regional warehouse. The article explains how they were able to error proof the workstations and improve their training to the point that they could hire folks with significant disabilities that would otherwise be thought to be unemployable.

It’s a story about applying lean concepts to help solve a big societal problem, and make a profit at the same time. Kinda made my heart go pitter-patter, and opened my eyes to the possibilities for lean to help save the world. Makes me want to quit making junk people don’t need, and instead apply my skills on something that solves a real problem.

The article is called “Erasing ‘Un’ from ‘Unemployable’”, Thursday Aug 2 WSJ Marketplace section. The photos show some of their workstation, which look very well done (highly visual, seemingly ergonomic).

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