Process correction
Corrective action metrics or plans eliminate an identified problem by proposing appropriate solutions. A corrective action plan aims to provide a standardized method that would help assess a defect and give the recommended corrective action for correction. Corrective actions are built on accurately identifying the root causes of various problems that need improvement, and one of the main reasons why root cause analysis is vital to creating action-oriented protocols for critical to-quality defects. An effective corrective plan accurately identifies root causes and then provides a transparent and standardized protocol to halt and correct errors in a process at the earliest point possible.
Error-proofing
The ideal solution to errors and defects is to devise methods that prevent them from occurring altogether. Error prevention or Error-proofing is known as" Poka-Yoke" in Japan. "Poka" means inadvertent errors, and "Yokero" means to avoid. Poka Yoke is credited to the Japanese quality consultant Shigeo Shingo. PokaYoke is about stopping the process when an error occurs by identifying the source and seeking to eliminate it.
Poka Yoke is simply a process mechanism designed to prevent a mistake from being made. Well-designed Poka Yoke will eliminate or hugely reduce the opportunity for an error or make a mistake so apparent at first glance that the chance of the defect reaching the customer is negligible. Poka Yoke is closely tied to the root cause analysis since it is used to prevent the causes that give rise to process defects. Poka Yoke methods can include such actions as the creation of a checklist, an alteration in the sequence of operations that allows error detection, a computer data entry form that acts as a double check, a message that reminds the user to complete or check a task before allowing them to proceed, a double entry password, and many other possible creative process problem solutions.
There are two main approaches to Poka Yoke correction:
- Type 1 corrective action, usually believed to be the most effective form of process control, is a type of control that, when applied to a process, eliminates the possibility of an error condition from occurring.
- Type 2 corrective action, also known as the detection application method. This control discovers when an error occurs and stops the process flow or shuts down the equipment so the defect cannot move forward.
