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Mistake-Proof It! Course Outline -- 4 Units

Unit 1 - Mistake-Proofing Primer
Lesson 1: What is Mistake-Proofing?
· Rewriting Murphy's Laws.
· Exploring the source of mistakes.
· The mindset necessary for mistake-proofing.
Lesson 2: Mistake-Proofing in Everyday Life.
· Common examples of mistake-proofing all around us.
· Using these examples to trigger ideas at work.
Lesson 3: Why Errors Are Made.
· How process inputs create process outputs.
· Why the root causes of errors must be identified.
Lesson 4: Inspecting vs. Mistake-Proofing.
· The limitations of inspection.
· Why prevention is always more powerful than detection.
Lesson 5: How Mistake-Proofing Works.
· The language of mistake-proofing.
· The role of teams in mistake-proofing efforts.
Challenge: An assessment of the learner's progress in this unit.

Unit 2 - Effects of Mistake-Proofing
Lesson 1: Approaches to Mistake-Proofing.
· Exploring the 8 forms of mistake-proofing solutions.
· Guidelines for selecting a mistake-proofing approach.
Lesson 2: Forced Control Devices.
· Delving into the four families of devices and methods used to achieve a forced control effect.
Lesson 3: Shutdown Devices & Warning Alarms.
· Examining 10 common families of sensors used to achieve a shutdown effect.
· Investigating 4 families of audible alarms and 4 families of visual alarms used to achieve a warning effect.
Lesson 4: Sensory Alert Devices.
· A look at the use of color-coding, missing-in-action clues, and other aids to achieve a sensory alert effect.
Challenge: An assessment of the learner's progress in this unit.

Unit 3 - Implementing Mistake-Proofing Solutions
Lesson 1: Integrating Mistake-Proofing & Problem Solving.
· How to incorporate mistake-proofing solutions into common problem-solving processes.
Lesson 2: Practical, Feasible, & Cost Effective Solutions.
· Assessment techniques for determining the practicality, feasibility, and cost-effectiveness of your mistake-proofing solutions.
Lesson 3: How to Keep Solutions from Being Overridden.
· Tips for keeping your mistake-proofing solution from being ignored or disabled.
Lesson 4: How Robust is Your Solution?
· Assessment techniques for determining how robust your mistake-proofing solutions are.
Lesson 5: Complementary Tools.
· How to use ten continuous improvement tools to complement mistake-proofing efforts.
Challenge: An assessment of the learner's progress in this unit.

Unit 4 - Mistake-Proofing in Action (Eight real-life examples in a variety of settings.)
Lesson 1: Mistake-Proofing in High Volume Manufacturing.
· Nowhere are the benefits of mistake-proofing more evident than in high volume operations.
Lesson 2: Mistake-Proofing in Assembly Operations.
· Mistake-proofing is a perfect tool to prevent assembly errors.
Lesson 3: Mistake-Proofing in a Job Shop Environment.
· Mistake-proofing in short-run job shops can make the difference between profitability and bankruptcy.
Lesson 4: Mistake-Proofing in Process Industries
· Mistake-proofing is at the core of complex chemical operations.
Lesson 5: Mistake-Proofing in Equipment Set-up.
· Mistake-proofing is an important element of set-up reduction.
Lesson 6: Mistake-Proofing in the Office.
· Mistake-proofing is not just for plant operations.
Challenge: An assessment of the learner's progress in this unit.