Failsafe Your Processes

Description

INTRODUCTION

Failsafing , in many forms, has been part of our everyday lives, knowingly or unknowingly, for many years. Failsafing is something like protecting ourselves against some foreseen or unforeseen failure in the activity or process we are engaged in. There are many examples like going to the airport earlier than scheduled, Safety Bolt in addition to the main door lock, Child lock in cars, wash basin sensor to stop water wastage due to an open tap etc.

Failsafing is also known by many names; such as ‘Poka-Yoke’, ‘Mistake proofing’, ‘Fool proofing’. Failsafing can be Designed-In , planned In-Process or act as a Detection. Failsafing today is extensively used in the automotive and other engineering industries. It is today being widely deployed in the service industry as well.

LEARNING OBJECTIVES

The objective of this course is to understand what is Failsafing, understand methods and techniques of preventing defects from occurring or detecting them prior to defects reaching the customer. We will discuss various types of Failsafing approaches, the strategies to be adopted, the steps for implementation and benefits of Failsafing.

We will discuss about various Failsafing devices used in manufacturing through several examples and case studies. We will also discuss how to organize for Failsafing in your organization. Apart from manufacturing, we will also discuss implementation of Failsafing in the Service industry.

The course will offer many mid-course learning checks and will offer additional reading resources.

The Failsafe Your Processes course is developed based on decades of front-line automotive industry experience of the instructor. 

WHO SHOULD TAKE THIS COURSE

This course on Failsafe your Processes is designed to be a comprehensive course on the concepts of failsafing. It is designed for professionals that either encounter issues due to lack of failsafing at workplace or would like to improve their outcome by proactively working to prevent (failsafe) failures.

It is designed for a wide variety of audiences like:

• Engineers
• Supervisors
• Managers
• Sales Manager
• Support and service professionals
• Quality Engineers and managers
• Production Line Managers and Supervisors
• Manufacturing Professionals
• Line operators and work cell supervisors

 COURSE CONTENT 

• INTRODUCTION
• WHAT IS A FAILURE
  • Definition & Criteria of Failure
  • Types and Causes of Failure
• WHAT IS A DEFECT
  • Definition of Defect and its impacts
  • Types of Defect – Parts 1 and 2
  • Causes of Defects
• UNDERSTANDING A FAILSAFE
  • Filing Cabinet
  • Plug and Socket
  • Cooking Gas Burner
  • Cell Phone SIM Card
  • USB Connector
• FAILSAFING
  • Types of Mistakes or Errors
  • Concept of Zero Defect
  • History of Failsafing
  • Definition of Failsafing
  • Purpose of Failsafing
  • Types of Failsafing – Parts 1 and 2
  • Setting and Regulatory functions
  • Benefits of Failsafing
• FAILSAFING IMPLEMENTATION
  • Defect Detection & Prevention Strategy – Parts 1 and 2
  • Failsafing Strategies
  • When to Use Failsafing
  • 10-Steps to Failsafing
• FAILSAFING DEVICES
  • Commonly Used Failsafing Devices in Manufacturing
  • Examples of failsafing devices
  • Types of sensing devices
  • Physical contact sensors
  • Physical contact sensors – Touch switch
  • Non-contact sensors – Parts 1 and 2
  • Energy sensors
  • Warning sensors
• ORGANIZING FOR FAILSAFING
  • People
  • Visual Aids
  • Visual Aids – Working Failsafe Boards
  • Visual Aids – Failsafing Tags
  • Visual Aids – Failsafing R-Y-G Status chart
• FAILSAFING CASE STUDIES – MANUFACTURING
  • Mfg Case Study #1
  • Mfg Case Study #2
  • Mfg Case Study #3
  • Mfg Case Study #4
  • Mfg Case Study #5
  • Mfg Case Study #6
  • Mfg Case Study #7
  • Mfg Case Study #8
  • Mfg Case Study #9
  • Mfg Case Study #10
• FAILSAFING CASE STUDIES – OTHER INDUSTRIES
• FAILSAFING IN THE SERVICE INDUSTRY
  • Failsafing in Service Industry
  • Types of Server errors / Server failsafes
  • Server error – Task Error
  • Server error – Treatment Error
  • Server error – Tangible Error
  • Types of Customer errors / Failsafes
  • Customer error – Preparation Error
  • Customer error – Encounter Error
  • Customer error – Resolution Error
  • 9-Steps to Service Failsafing
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ