1st Edition

Mistake-Proofing for Operators The ZQC System

    96 Pages
    by Productivity Press

    The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. This book introduces operators and assembly workers to the basic methodology of ZQC in an easy-to-read format that covers all aspects of this important manufacturing improvement strategy.

    Mistake-Proofing for Operators includes the instructional features that are the signature of the Shopfloor Series. In this series Productivity Press has taken the lead in adult education by teaming with instructional designers to develop complete programs for frontline learning. The goal: to place powerful and proven improvement tools such as ZQC and mistake-proofing in the hands of your company's entire workforce.

    Winner of the 1990 Shingo Prize for Excellence in Manufacturing, Mistake-Proofing for Operators is based on Zero Quality Control: Source Inspection and the Poka-Yoke System by Shigeo Shingo

    Preface Chapter 1: Getting Started
    Chapter 2: Introduction to Zero Quality Control
    Chapter 3: Basic Elements of the ZQC System
    Chapter 4: Using Poka-Yoke Systems
    Chapter 5: Examples of Poka-Yoke Applications
    Chapter 6: Reflections and Conclusions
    About the Authors


    Productivity Press Development Team

    "This book, with its unique approach to learning, allows individual employees to understand and apply the critical discipline of mistake-proofing to accomplish the goal of zero defects."
    Gifford Brown, Plant Manager, Ford Motor Company, Cleveland Engine Plant 2 06/01/04

    "Mistake-Proofing for Operators presents Dr. Shingo's concept of ZQC in a format for maximized breadth and depth of learning. The best poke-yoke opportunities are discovered by production employees and can often be employed for only a few dollars but only if employees have been trained to identify the opportunities. Any manager who truly wishes to empower his or her employees to drive out defects should use this book for ZQC training."
    Bruce Hamilton, VP of Operations, United Electric Controls Company 06/01/04