Design errors occurring in the issue of products are costly, they lead to delays, rework, loss of customer creditability and poor morale throughout the company. A high error rate can occur in sales, engineering and production.
While people cause errors, management has a responsibility to provide processes that make it very difficult for errors to occur. Shigeo Shingo introduced a lean principle of poka-yoke of fool-proofing. Poka-yoke provides processes that do not allow an operator to make an error.
By working differently, companies can reduce the error rate. Product standardisation ensures errors cannot occur, and when an error is detected it can be remedied at the source. Quality information can be available to anyone authorised to access it.
Problems:
When information transfers, processed or issued errors can occur. 99% of errors are human error. The likelihood of error increases with the unnecessary processing and transferring of information.
Sales create errors by referring to obsolete or inaccurate information. Estimation processes always generate an error. Untested solutions can generate errors and rework. On occasions, Sales request product details from Engineering. This work assumes a high priority and is usually unscheduled. Engineering provides the information required at the expense of delaying scheduled work.
Engineering is often responsible for creating design errors by working on product solutions in isolation. During the transfer or processing of information, there is an increased risk of errors and variances occurring. Checking procedures are used to reduce the impact of these errors which adds further delays and costs to the product. Variances occur with the involvement of different people, leading to slight changes in the design or components used. These variants may add to the product complexity, increasing inventory and uncertainties in the product performance.
Solution:
Using principles of poka-yoke, create a product standard reference library to ensure errors cannot occur. Ensuring that the standards are complete, accurate and contain all the data required by all stakeholders. Standard information can be maintained and easily secured. Current, validated information is available to anyone who is authorised to access it. All standard products are thoroughly checked to eliminate design and integration errors. When errors are detected, correct these errors at source ensuring continuous improvement. Product standardisation reduces the number of processes required and the frequency information needs to be transferred. Information stored in the standard library is accurate and up to date and therefore reliable.
Engineering can work on product design without production or sales deadlines. The product can be considered as part of an overall family to ensure all parts and products integrate correctly. By using proven product designs, Sales can reference products with confidence. Production receives product requirements that are proven, sufficiently detailed and delivered faster.
Encourage incremental product development. Product life extends by adding new features and options required by the market. Manufacturing optimisation becomes a key priority of product design.
Advantages from different perspectives
Achieve shorter delivery times
Fewer bottlenecks requiring management attention
Receive products and information faster with fewer errors.
Quality product information on demand
Reduce sales support and product fulfilment costs
Complete product engineering more efficiently
Achieve shorter delivery times
Reduce risk as fewer processes and transfers of information
Fewer bottlenecks requiring management attention
Increased customer satisfaction by receiving products faster with fewer errors.
Improved productivity as more work is possible
Increased profitability with the reduction of cost and risk, while improving productivity
Better cash-flow as delivery times shorter and final payments made on time
Reduce sales support and product fulfilment costs
Fewer bottlenecks requiring management attention
Improved productivity as more work is possible
Increased profitability with the reduction of cost and risk, while improving productivity
Increased customer satisfaction by receiving products faster with fewer errors.
Quality product information on demand
Reduce sales support and product fulfilment costs
Achieve shorter delivery times
Reduce risk as fewer processes and transfers of information
Fewer bottlenecks requiring management attention
Improved productivity as more work is possible
Less risk, fewer processes and transfers of information
Fewer bottlenecks requiring management attention
Increased customer satisfaction by receiving products faster with fewer errors.
Product design planned and managed without production deadlines
Quality product information on demand
Less risk, fewer processes and transfers of information
Fewer bottlenecks requiring management attention
Increased manufacturing optimisation support
Further help and assistance
Gatehouse Design are specialists in product standardisation, product configuration and design automation. We can help companies develop highly effective product strategies, maximising profitability, productivity and customer satisfaction. We can help you reduce product error rate and improve the efficiency of your business. Please contact us to discuss any product design related issues that you may have.
Peter Slee-Smith founded Gatehouse Design in 2012, a Chartered Mechanical Engineer with more than 30 years experience in industrial design. Peter qualified with a Masters Degree and has held senior positions in many leading engineering and product manufacturing companies. He is passionate about product design efficiency and has written many articles on the subject. Based in Littleport just outside Ely in Cambridgeshire, Gatehouse Design specialises in product standardisation, configuration and design automation.
