Error Proof

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Error Proof 2018-03-07T03:22:31+00:00

Error Proof – How to Stop Daily Goofs for Good

How Error Proof are Your Processes?

Six sigma levels of quality cannot be achieved by asking people to be careful or disciplining those who goof. Instead, we have to error proof our work processes to sustain excellent levels of performance.

Why do so many people struggle to capture their key process errors that occur daily? How can we anticipate, and minimize, the potential for human error as work systems are designed and improved? How can a work system be designed to achieve very low error rates on a consistent basis? How do you get your teams to consistently use error reduction techniques? The key lies in using proven work system designs and practices to help minimize the daily potential for human error. This book contains many best practices to help you achieve this goal.

Significant examples of success – where error and incident rates are very low – do exist. The Blue Angels excel at work planning and review. Pal’s quick serve restaurant chain has a superior training and certification system. Oil field workers consistently achieve near zero safety incident levels that many organizations would consider as being unobtainable. How do these groups of people find ways to standardize their work practices and minimize errors in very dynamic settings? The Error Proof book and workshop will show you how to apply multiple ‘best in class’ work system designs and practices, and in turn, help you accelerate your performance improvement efforts.

EXPLORE More: Process Improvement Strategies

How can you error proof your key work systems and processes?

Key error proofing and process improvement concepts will be introduced throughout the day as participants work through multiple exercises that help illustrate the five key strategies that exist for ‘error proofing’ a process. 

The workshop facilitator will also describe key lessons that have been learned relative to deploying error proofing improvement techniques across all work process types. The work system integration process for using these improvement tools is perhaps more important, as it is the deployment and integration of these tools with other techniques and processes will drive sustained error and defect reduction. Case study examples, such as adding the consistent use of improvement tools to job descriptions and personal development plans, and linking key results indicators to each employee’s profit sharing plan, will be used as examples.

DISCOVER More: Are You Fit for Duty?

Error Proof Model

What will you learn in this interactive error proofing workshop?

  • Apply proven work practices that are key to reducing daily human error rates
  • Use lean data capture techniques to help identify key error types and frequencies
  • Better measure the effectiveness of your error proofing approaches
  • Make improvements to the error minimization strategies you already use
  • Develop your own prioritized, ‘error proofing’ plan

Are you interested in bringing this two day “Error Proof – How to Stop Goofs for Good” workshop into your organization?

If you were unable to make my most recent workshop on this topic, consider bringing this interactive systems changing workshop to your own facility. If you are interested, send me a e-mail at and tell me which workshop you would like to bring into your facility. I will then work with a contact person from your location to arrange the workshop logistics, and more importantly, to customize the workshop to meet the specific needs that you have.

Who created the Error Proof book and workshop?

The “Error Proof – How to Stop Daily Goofs for Good” book and workshop was designed by Kevin McManus, who has served as an industrial engineer, Production Manager, Plant Manager, and Director of Quality during his 35 year business career. Kevin has facilitated over 40 value stream mapping and mistake proofing workshops, and has been teaching the TapRooT® root cause analysis process internationally for fourteen years. He has also served as an Examiner, Senior Examiner, and Alumni Examiner for the Malcolm Baldrige National Performance Excellence Award for eighteen years. Kevin writes the monthly Performance Improvement column for Industrial Engineer magazine.

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Stopping Daily Goofs Handout Part 1

Stopping Daily Goofs Handout Part 2

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