Strategic Error-Proofing: Achieving Success Every Time with Smarter FMEAs

While FMEA  has helped many companies improve quality by teaching them how to avoid what can go wrong, it doesn’t show how to make things go right. That is what the Success Every Time (SET) does. Developed by renowned manufacturing visionary John Casey, SET defines a logic stream for engineers to strategically incorporate no-cost or low-cost error-proofing devices to help production operators.

When SET is executed completely, failure is not an option. The operators interface with their parts and tools in such a way that either the product is made correctly, or the product/process is stopped. Operators can make only good parts—nothing else. For this reason, proper implementation of SET drives higher first time yield, increases customer satisfaction, improves warranty claims, improves profits, and helps you compete.

John J. Casey has published multiple articles on quality initiatives and is well recognized in the Automotive Industry. Mr. Casey is seen as an automotive industry visionary and is cited as the father of GM’s Global Quality Tracking System that was the cornerstone of GM’s 85% improvement on inbound quality over a 4-year period.

Table of Contents

Introduction 
Part 1: Getting Started with Success Every Time 
Chapter 1: FMEA, Poke-Yoke, Mistake-Proofing, and Error-Proofing: Sorting Out the Terminology 
Chapter 2: Success Every Time and Quality Improvement 
Part 2: The Critical Phases of Success Every Time 
Chapter 3: Strategic Monitoring of the Critical Elements 
Chapter 4: Phase I of the Success Every Time Method: Part Level
Chapter 5: Phase II of the Success Every Time Method: Set-Up Level 
Chapter 6: Phase III of the Success Every Time Method: Parameter Level 
Part 3: Perfecting and Monitoring Your Error-Proofing Devices 
Chapter 7: Designing Parts That are Device-Compatible 
Chapter 8: Investing in Your Devices 
Chapter 9: Creating Great Devices, Placing Them, and Verifying Their Success 
Part 4: Success Every Time as a Corporate-Wide Strategy 
Chapter 10: The Strategy Behind Success Every Time 
Chapter 11: Putting it All Together

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