Solutions :: Error Proofing

Error Proofing vs. Mistake Proofing

Error proofing and mistake proofing are two different concepts. Error proofing means to prevent an error from occurring. Mistake proofing means to detect an error that has occurred. ToolWorx employs both concepts in our data collection systems.

An example of an error proofing system is ToolWorx's PLC Printer. This printer hooks directly up to a PLC that signals the printer which part is being made. The printer then prints one label with the correct part number. An error cannot be made, therefore this process is "error proofed". You can read a case study of an automotive supplier who implemented several PLC Printers for error proofed shipping by clicking here.

Another example of an error proofing system is the ToolWorx SmartPack™ End-Of-Line Error Proofing System. This system eliminates the potential for mislabeling errors at end of manufacturing lines before you pack or sequence production (called In-Line Vehicle Sequencing, or ILVS). You can read more about this unique system by clicking here.

An example of a mistake proof system is embedded in ToolWorx's TWLot™ Lot Track system. This system includes several routines to detect errors before they get any further. For example, in the Component Link routines, the system validates the component material brought to the line against the Bill of Material to ensure that it is the right component as well as the correct engineering level. If an error is detected, the operator is notified by a display, an alarm, or stopping the line, whichever is appropriate. An error can be made (the operator can bring the wrong parts to the line), but it is always detected by the system before the wrong parts are used; therefore, this process is "mistake proofed".

Another example of mistake proofing is used in TWLot™ and answers the age old question "How can I tell if someone hasn't scanned?". The system tracks when a component container is brought to the line. Then, a Component Aging Report is generated daily that lists all components that have been brought to a line but have not been scanned to a Finished Goods or Work-In-Process container. This way, a Supervisor can track down the status of "old" components to ensure that they are still waiting for use. The aging report will help supervisor narrow down which operators/lines are missing their scans.

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For a copy of our presentations on Error Proofing including customer case studies,
click here.