OnDemand Webcast: Proven Methods to Abnormality Management and Error Proofing (Part 3)
February 9, 2023
Operations teams may be lacking visibility to abnormalities as they occur or may struggle to understand the best approach to quickly address the root cause.
Not having the ability to identify and rapidly respond to an abnormality means risking potential line shutdown, re-work, or maybe even a recall. SafetyChain hosts operations experts David Hicks and Tim Nickerson from TBM as they build the steps needed to formalize and implement a proactive abnormality management program – including methods to error-proof your operations.
On this webinar, you will learn:
Approaches to successfully implement abnormality management
Techniques for auditing countermeasure effectiveness
Hierarchy model of error-proofing and projected cost savings
What does abnormality management in manufacturing operations mean?
Abnormality management refers to the ability to quickly identify when something is not performing as expected and take immediate action to correct it. The video explains that abnormalities are often hidden by delayed reporting or informal workarounds. A strong management system makes deviations from standard visible in real time, allowing teams to respond before problems escalate into quality issues, downtime, or missed deliveries.
How does error proofing support better execution and quality?
Error proofing supports better execution by designing processes so mistakes are difficult or impossible to make. The video emphasizes that relying on inspection or individual vigilance is unreliable. Instead, error‑proofing methods build safeguards directly into the process, reducing variation and preventing defects at the source. This approach improves quality while lowering rework, scrap, and operational stress.
Why is a management system essential for sustaining abnormality management and error proofing?
A management system is essential because abnormality management and error proofing only work when they are reinforced daily. The video highlights that without consistent leadership routines, clear standards, and follow‑up, processes drift and problems become normalized. When embedded into a disciplined management system, abnormality detection and error proofing become part of how the operation runs every day, enabling sustained performance and continuous improvement.
