How would you error proof this material handling / logistics situation? I have a few ideas, but thought this would make for interesting discussion. I won't set up a “spend no money” rule, but cheaper and simpler ideas are always best.Here's a pallet of material at a hospital (click on the photo for a larger view). There's a pink sign that says, “Carrier, DO NOT Double Stack or Break Shrink Wrap.”
Barking orders at people is a very weak form of “Error Proofing” (it isn't really error proofing at all). What if they don't see the pink sign? What if they don't respect it? Would you ever know? Can you explain “why” if you have to use a sign?
If you absolutely needed to ensure that the pallet wasn't double stacked, can you think of a way of error proofing that? Click “comments” to submit your idea. No prize, other than bragging rights amongst your Lean peers.
On a very coincidental note, at the airport buying water today, I overheard the employees talking about a pallet of bottled water that got crushed because it was doublestacked and shouldn't have been. Maybe there's a market for something here.