What are the background and solutions for the issue of "different model number" installations not decreasing?
[Training Video] "The Root Cause of Repeated Mistakes: 'Wrong Model Number.' Strengthening Systems and Education to Prevent 'Wrong Model Numbers' is Key.
Are you struggling as a team leader with the ongoing issue of "incorrect model number" installation mistakes in the assembly process? ● Parts that look similar are being mixed up during assembly ● Visual checks alone cannot completely prevent errors ● Mistakes are discovered only during final inspections or just before shipping These problems stem from a work system that relies solely on the attention and experience of the workers, and fundamental countermeasures are needed. To prevent "incorrect model number" mistakes, it is essential to create a system that does not depend on the workers' attention and to review the training. By approaching this from both technical and educational perspectives, we can achieve a reduction in errors and an increase in productivity. At LinkStudio, we produce video materials that help with parts identification and the visualization of work procedures. If you have any inquiries regarding the review of educational content or the development of teaching materials, please feel free to contact us. *For more details, please do not hesitate to reach out to us.
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Proposal for Solutions | Review of Systems and Education to Prevent "Incorrect Model Numbers" To prevent mistakes related to "incorrect model numbers," it is necessary to create systems that do not rely on the attention of workers and to review education. Specific measures include: ● Attaching QR codes to parts and jigs and implementing confirmation through scanning ● Clearly stating photos and characteristics of parts in work instructions and manuals ● Sharing examples of differences between similar parts and installation mistakes during training for new employees These initiatives will make it easier for workers to select the correct parts and help reduce the occurrence of mistakes.
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Implementation Steps | Procedures for Preventing "Model Number Differences" STEP 1 | Understand the Current Situation of Errors Analyze the number of past errors due to model number differences and their causes to grasp the overall picture of the problem. STEP 2 | Establish Identification Labels and Verification Procedures Clearly label parts and jigs, and specify verification procedures in the work instruction manual. STEP 3 | Review the Training Program Share methods for identifying parts and examples of errors through new employee training and regular drills to reinforce knowledge. STEP 4 | Verify Effectiveness and Make Improvements Monitor the occurrence of errors after implementation and revise or improve measures as necessary.
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P3
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OTHER
Model number/Brand name
Custom-made training video
Applications/Examples of results
Introduction of Success Case | Utilizing QR Codes to Eliminate "Wrong Model Numbers" In a molding processing factory, the occurrence of defective products due to "wrong model numbers" was a significant issue. To address this, QR codes were affixed to parts and jigs, and a scanning confirmation system was implemented, resulting in the following outcomes: ● Mistakes related to "wrong model numbers" were reduced to zero ● The confirmation work of operators was streamlined, leading to increased productivity ● The training period for new operators was shortened, enabling them to become effective contributors more quickly Thus, an approach that combines technology and education has contributed to the reduction of errors and the improvement of productivity.
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| Model number | overview |
|---|---|
| Establishment of education and systems to prevent "model number discrepancies" 1️⃣ | Clearly identify parts and jigs with distinct markings |
| Establishment of education and systems to prevent "model number discrepancies" 2️⃣ | Include photos and features of parts in the work procedures manual |
| Establishment of education and systems to prevent "model number discrepancies" 3️⃣ | Share examples of differences between similar parts and installation mistakes during new employee training |
| Establishment of education and systems to prevent "model number discrepancies" 4️⃣ | Conduct regular education and training to reinforce knowledge |
