The main measures to prevent human error include:
Material inspection: After the materials arrive at the production warehouse, the material handler should inspect all materials and confirm that they are correct before sending them to the production line. ‌
Loading verification: When installing the material roll onto the Feida, the operator should reconfirm the material and notify the quality control (QC) personnel for verification.
First article inspection: Before producing the first board, conduct a first article inspection to confirm its accuracy before officially starting production.
Mid way material replacement verification: When material replacement is required during the production process, repeat the above verification steps.
Use error prevention system: Utilize barcode technology and PDA (Personal Digital Assistant) system to automatically verify materials and reduce human errors. ‌
Strict production control: Provide sound and light warnings for incorrect materials during loading, receiving, and changing processes. Once the materials are used incorrectly, the system will immediately sound an alarm and production will be prohibited from continuing. ‌
The detailed operation steps are as follows:
Material inspection: The material handler inspects all materials, confirms that the material identification, quantity, etc. are correct, and then sends them to the production line.
Loading verification: When installing the material roll onto the Feida, the operator uses a barcode scanner to scan the material, confirms its accuracy, and then notifies the QC personnel for verification. ‌
First article inspection: During the production of the first board, a first article inspection is conducted to confirm its accuracy before officially starting production.
Mid way material replacement verification: When material replacement is required during the production process, repeat the above verification steps.
Using error prevention system: Using barcode technology and PDA system, employees scan station numbers and material barcodes during loading and receiving, and the system automatically checks. In case of errors, an alarm is triggered and the line body is locked.
Strict production control: Provide sound and light warnings for incorrect materials during loading, receiving, and changing processes. Once the materials are used incorrectly, the system will immediately sound an alarm and production will be prohibited from continuing.
Supplementary measures and precautions:
Training and Education: Regularly train operators to improve their proficiency in using error prevention systems.
Regular maintenance and inspection: Conduct regular maintenance and inspection of the error prevention system to ensure its normal operation.
Record and Tracking: Keep records of each loading, receiving, and changing of materials for tracking and improvement.