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Pro Manual! Human Error and Mistake Prevention / Recurrence Prevention Measures

Thoroughly address human errors in the manufacturing industry from all angles! Please choose from practical manuals, procedure documents, or on-demand video explanations.

★Traditional human error countermeasures have been reactive measures (whack-a-mole) that address issues after they occur. ★From the mindset that "humans make mistakes," we aim to reduce errors to as close to zero as possible. Our research institute scientifically analyzes human (operator) behavior and work processes, proposing a system (management framework) that includes reliability design to prevent errors, work training, and clarifying the role of change point managers in manufacturing processes. ★The seven steps for human error countermeasures are as follows: 1. Reliability design of processes incorporating preventive measures (poka-yoke) (QC process diagrams/work instructions) 2. Work observation and improvement using IE methods (environmental improvements/motion principles and ergonomic approaches) 3. Feedback to work standards 4. Work breakdown and training 5. Involvement of managers in daily operations (work observation and guidance) 6. Investigation of root causes and countermeasures when errors occur (structuring rules and pointing out deficiencies) 7. Knowledge informationization (knowledge management)

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Pro Manual! Case Studies on Quality Issue Prevention Measures for Administrators and Leaders

Introducing measures against human error and troubleshooting for overseas production subcontracting factories!

Table of Contents Chapter 1. Corrective Actions and Recurrence Prevention Measures 1. Error Proofing 3. Cause Investigation and Measures Using the 5 Whys Method 4. Corrective Actions / Recurrence Prevention / Horizontal Deployment 5. Action Plan Format Chapter 2. Various Analysis (Cause Analysis) Methods 1. Logical Thinking 2. 5 Whys Analysis 3. Cause and Effect Diagram 4. FTA Analysis 5. Troubleshooting Method Chapter 3. Case Studies on Quality Trouble Measures Case Study 1: Operational Errors Case Study 2: Picking Errors of Difficult-to-Distinguish Products Case Study 3: Process Skipping Due to Work Interruptions Case Study 4: Inadequacies in External Submission Documents Case Study 5: Violations of Work Instructions During Overseas Factory Transfer Case Study 6: Neglecting Problems Case Study 7: Recent Frequent Operational Errors in the Process Case Study 8: Ensuring Compliance with Established Procedures Case Study 9: Contamination with Unprocessed Materials Case Study 10: Smoke Issues with Products Passed in Shipping Inspections Case Study 11: Variability in Process Characteristics of Parts Case Study 12: Issues with Injection Molding Specific Technologies Case Study 13: Foreign Matter Adhesion in Multiple Processes Case Study 14: Machine Failures Case Study 15: Chronic Defect Measures Case Study 16: Component Damage Defects in the Market

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