Design of Human Error Prevention Program for Manufacturing Processes

Abstract

During the 2012 Quality Management Review, Stryker Corporation identified that 20% of the company wide Product Field Actions were due to human factor related incidents. The goal of this project was to develop a Human Error Prevention Program that could be deployed in any manufacturing facility across the world. It incorporated the development, design and testing of a series of tools and methodologies to be incorporated within this program. These tools and methodologies would be tested in two pilot sites; Cork Ireland and Mahwah, United States; with the purpose of ensuring the results of the program’s deployment was transferrable to any manufacturing site. This project led to an average of 41% of improvement of key performance business process indicators. This project has been developed under the Lean Plan-Do-Check-Act (PDCA) Cycle methodology, in order to identify real systematic root causes and enable the company to reduce human factors incidents. Key Terms - Lean Plan-Do-Check-Act (PDCA) Cycle Methodology, Product Field Actions.