Zero-Defect Quality (ZDQ): Mistake Proofing and Fail Safeing

ZDQ (Mistake Proofing and Fail Safeing) is a process to insure 100% defect-free quality at the source….which means, 100% quality management on the process 100% of the time as the product is made. ZDQ is not sampling inspection after the fact, it is not 100% “clear and sort” inspection, it is not statistical process control (SPC), it’s much more effective than any of these.

ZDQ has 2 parts and 4 levels of Quality Control:

Level 1 Mistake Proofing = eliminating sources of product defects

Level 2 Mistake Proofing = preventing defects from being made

Level 3 Fail Safeing = detecting a defect as soon as it’s made (line stop)

Level 4 Fail Safeing = managing the defect that is made (countermeasures)

Learning Objectives:

1. Why Mistake Proof and Fail Safe your processes?
2. What is ZDQ?
3. Poke Yoke
4. Jidoka
5. Judgement Inspection vs. Informative Inspection vs. Source Inspection
6. Is 99.97% quality good enough?
7. Some common everyday examples of MP and FS
8. Root Causes of Human Errors
9. MP/FS 12 Step Process
10. Seven MP/FS Principles
11. Red Flag Conditions
12. Errors of Perception, Errors of Memory, Errors of Motion
13. MP/FS Applications

Duration: 2 days

JCM Work Designs/The Lean Sigma Team can design and conduct this workshop to meet your specific needs.  Please contact us for a formal proposal.