Defect Prevention Kaizen
Defect prevention at the bottleneck operation is critical for success because scrap and rework have a non-linear impact on cycle time and throughput in the process. This is because scrap/rework at the bottleneck consumes production time as well as capacity. In batch processes, a 10% increase in scrap can increase batch size requirements by as much as 50%! For these reasons, defect prevention Kaizens can have very dramatic impacts on the process and profitability. Participants learn to apply mistake-proofing techniques such as poka-yoke, design for manufacture, source inspection, and adaptive control. .

Typical results:

• DPMO reduced or eliminated through the implementation of poka-yoke devices
• Non-linear improvement in batch sizes and associated cycle time
• Improved customer satisfaction through higher shipped product quality