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Application of Human Error Prevention
Principles
Rajinder Singh
Mahindra Institute of Quality
Mahindra and Mahindra Ltd
Mumbai
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INTRODUCTION : Mahindra and Mahindra Ltd
AUTOMOTIVE & FARM
SECTORS
FINANCIAL SERVICES
SECTOR
INFORMATION TECHNOLOGY
SECTOR
SYSTEM SECTOR
MAHINDRA PARTNERS
TWO WHEELER SECTOR
INFRASTRUCTURE &
REALITY SECTOR
AFTERMARKET SECTOR
HOSPITALITY SECTOR
DEFENCE SYSTEM
10 BUSINESS SECTORS : USD 16 BILLION
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Mission
MIQ aims at making
“Quality”
a way of life
&
imparting TQM competence
to organizations
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Why Human Error Prevention at Mahindra?
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

Many Manual assembly operations
Increasing use of temporary workmen
Complexity of operations
Conventional means like education and training
have not yielded zero defects
Areas selected for application:
1. Press Shop
2. Body Shop
3. Assembly Line
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Human Error Proofing
Improvement of work operations,
including materials, machines and
methods, with the aim of preventing
problems due to human error.
Improve Human Beings
to Fit Operations
Improve Operations
to Fit Human Beings
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Mahindra’s Human Error Prevention Application Approach
1.Find out opportunities
for improvements
2.Horizontal
deployment
1.Monitor Quality
Indicators
2.Monitor Number of
Improvements
1.Design check list
2.Plan
Implementation
Strategy
3.Plan training
methodology
PLAN
ACT
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DO
CHECK
1.Training and involve all
officers and operators
2.Find out improvements
3.Implement solutions
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DEFECT
Flow Chart
PROCESS CONFIRMITY ANALYSIS (LO)
IS THE DEFECET
BECAUSE OF HUMAN
ERROR
N
FOLLOW QC STORY
Y
HUMAN ERROR CHECK LIST
DIFFERENT POSSIBLE SOLUTIONS
ANALYSE THE SOLUTIONS
ACTION PLAN
IMPLIMENT SOLUTION/S
CHECK
Y
EFFECTIVENESS
N
PROBLEM CLOSURE
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1) Training to
operators for
Understanding of
theory
2) Take 1 problem
from daily work
3) Put the problem
in Human Error
Prevention
Checklist
4) Generate
different solutions
5) Evaluate the
solutions on SPN
6) Select the
solution for
Implementation
7) Implement the
solution
8) Monitor the
effectiveness of
implemented
solution
TRIAN AND APPLY in QC CIRLCE
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HEP Case Studies
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Case Study 1 –
Missing or Wrong Spare
fuse assembly
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Concern – Missing Fuse or Wrong fuse getting
assembled in the fuse flap
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Before Process
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Improved Process
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Case study 2 –
Wrong badges fitment
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Concern – Wrong badges fitment
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After Process
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Case study 3 –
Unsafe Condition at Engine
compartment sub-assembly station
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Concern – Possibility of an unsafe condition at
Engine compartment station if Operator forgets
to clamp the fixture
Effect on Customer – Engine Compartment
falling down which may result in Accident !
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Before Process Video -
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Improved Process -
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Principle W ise Application
Principle
% Improvements
Elimination
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Replacement
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Facilitation
33
Detection
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Mitigation
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
Results and
conclusions
62% reduction in Quality
concerns due
to Human errors

52% reduction in incidents due to
unsafe acts
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Due to TEI in HEP, it was possible to
achieve good results

Improve operations to fit human beings
rather than only improving human
beings to fit the operations
Acknowledgements:
1.
Dr. Takeshi Nakajo from Chuo
University Japan
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THANK YOU
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