Error Proofing Terminology

It is our intention that this page will give an explanation of the various terms commonly used in error proofing - or in some cases Lean Manufacturing. Updating the page will be a continual operation - new terminology is appearing and new terms are being discovered by the author on an almost daily basis. Please feel free to email us if you require an explanation of a term not shown. Similarly, please advise us of any terms which you feel should be included. Thank you.

'A'
Active Error:
An error that has an immediate effect on the process

Alarm:
A device that provides indication that an error has occurred. The actual means of indication will vary depending on the process and operational environment.

Autonomation:
The automatic identification and control of errors or process defects. In a typical situation, this would involve the automatic stopping of a machine when an error is detected.


'B'
Black Belt
Six Sigma Black Belts are those who have experience of implementing improvements. They have typically received a minimum of six weeks training, have completed six sigma projects and have sat an exam to prove their competence.


'C'
Control Methods:
The means by which such as assembly or production is halted until error conditions have been corrected.

Conformance:
The acceptance that a product has met all the requirements of the specification.

Cycle Time:
The actual time taken for an operator or machine to completely process a product.


'D'
Defect:
Components that do not meet the required specifications or conformance requirements, and which will therefore lead to additional costs.

'E'
Environmental Factors:
The factors surrounding a process. Depending on the physical location, these could include such as lighting, noise, ambient temperature.

Error:
The failure of a process - manual or automatic - to meet the required standards. This could be the failure of an operator to fit a component, or select the wrong component in the wrong sequence.

'F'
Fail-safing:
Basically 'error proofing' but ensuring that a failure will not cause damage.

Flow Production:
A basic requirement of just-in-time production. In Flow Production, machines or operators are arranged so that the work piece moves in a continuous flow from station to station without stoppage.

Fool Proofing:
An occasionally used term to describe 'error proofing'. The term is not used to any great extent due to the inference that errors are due to fools or foolish actions - which is generally not the case.


'G'
Gemba:
A Japanese Kaisen term which refers to the actual workplace. Frequently it is used to refer to the shop floor.

Gembutsu:
The physical items - work pieces, machines, tools etc. - found at the work station.

Green Belt
A Six Sigma engineer who has not yet achieved the standard of Black Belt.


'H'


'I'
ISO9001:2000
The successor to ISO9000 Quality Standards. ISO9001:2000 is based on eight Quality Management Principles.


'J'
Jidhoka:
Synonymous with 'autonomation'. Jidhoka is some form of system or device that stops a machine - or operator - when a defective part has been identified.


'K'
Kaisen:
In essence, the philosophy of making continuous improvements to a process or operation, the purpose of which is to improve performance and cost effectiveness in small, incremental steps.

Kanban:
The Japanese word for 'sign'. A system where, when all the parts in a container have been used, a sign (a card or some other visible means) is displayed to advise that more parts are required. The Kanban card acts as the order form.

Kosu:
A measure of an operators productivity - referring to the number of man hours spent on an activity. The reduction of Kosu is always a target in lean manufacturing.


'L'


'M'
Muda
The Japanese work meaning 'waste'. In Kaisen speak, this refers to any form of waste - time or materials.


'N'


'O'


'P'
Pick by Light
An operator instruction system where the next part to be fitted or picked is indicated by an illuminated indicator - typical of the systems designed and manufactured by SpeasTech Inc.

Pick to Light
An alternative name for Pick by Light.

Poka Yoke
Poka Yoke is a Japanese term referring to mistake proofing. In order for a device or system to be regarded as poka yoke, it must give some form of indication to identify that an error is being made.


'Q'
QS9000:
The United States version of ISO9000. This was originally a system imposed by the leading automobile manufacturers on their suppliers.


Quality:
In its broadest sense, 'Quality' refers to the conformance to specification, design, delivery, production and post-sales services provided for a product.

QC:
Quality Circles:
a system originating in Japan (under the name 'quality control circles') where small groups of employees perform self improvement for the benefit of process improvement.


'R'


'S'
Seiri
One of the Japanese 'Five S's'. Identify and separate the necessary from the unnecessary. Dispense with the unnecessary.


Seiton
The second of the Japanese 'Five S's'. Place everything so that it is always easily accessible.


Seiso
The third of the Japanese 'Five S's'. Always clean-up - including in normally unseen places such as behind and under the machine.


Seiketsu
The fourth of the Japanese 'Five S's'. Make cleaning and checking routine procedures.


Shitsuke
The fifth of the Japanese 'Five S's'. Ensue that the other four S's are standardised to ensure continuity.


Six Sigma
Six Sigma is a process methodology which provides an increase in company or process performance, with a reduction in defects. Statistically, Six Sigma means a maximum of 3.4 erroneous or defective parts per million parts produced. Six Sigma training can now be done online by sixsigmaonline.org The company provides provides various Six Sigma training and certification courses including Black Belt Six Sigma Certification, Green Belt Training, DFSS Design for Six Sigma Courses and Certification.

SPC:
Statistical Process Control. The use of statistical techniques to provide quality control.


'T'
TQC:
Total Quality Control. The philosophy that everyone concerned with the production of a product, is responsible for quality - including managers and the workforce.

TQM:
Total Quality Management. A more frequently used term for TQC.


'Z'
ZQC:
Zero Quality Control. Perhaps not as it sounds, ZQC actually means "to make products with zero defects".