Improve equipment and material arrangements

Oct 13, 2025 by vinooalluri.com 135 views

Identification of Human Error Based on the Cream Approach and Proposed Improvement with the Poka-Yoke Method in the XXX Printing Unit

Introduction

Human error is a significant problem that often occurs in the production process, including in the XXX printing unit. It is defined as a person's failure in achieving the desired results when carrying out a series of mental and physical activities. According to Reason (1990) in Johan De Haan (2012), this error can lead to defective products. The XXX printing unit, which produces various printed products from paper such as forms, experienced this challenge in the printing section. In this section, the product is determined and formed in accordance with consumer demand and specifications. Unfortunately, printing operators in this company often only depend on experience and habits, without clear and standard work procedures. This has the potential to cause operational errors that produce product defects, which are recorded at 9.94% from the nine times the printing process. The defects include blurred, black/dirty, torn and wrinkled molds.

The Problem of Human Error in the XXX Printing Unit

The XXX printing unit is a company that produces various printed products from paper such as forms. The printing section is where the product is determined and formed in accordance with consumer demand and specifications. However, the company has experienced a significant problem with human error in this section. The printing operators often only depend on experience and habits, without clear and standard work procedures. This has the potential to cause operational errors that produce product defects. The defects recorded in the printing process include blurred, black/dirty, torn and wrinkled molds. The frequency of these defects is 9.94% from the nine times the printing process.

The Cognitive Reliability and Error Analysis Method (Cream) Approach

To identify the sources of human error in the XXX printing unit, the Cognitive Reliability and Error Analysis Method (Cream) approach was used. The Cream approach is a method designed to analyze human error and identify the cognitive functions that contribute to it. The results of the analysis show that the two most dominant cognitive functions in the process of printing and handling dirty products are execution and interpretation. Meanwhile, observation and planning have a smaller role in this process. The high human error probability (HEP) operator was recorded at 0.99999 for the printing process and 0.99789 for handling dirty products. Both of these values indicate that the risk of human error in this operation is classified as very high.

The Cream Approach Analysis Results

The Cream approach analysis results show that the two most dominant cognitive functions in the process of printing and handling dirty products are execution and interpretation. Execution refers to the physical actions taken by the operator, while interpretation refers to the mental process of understanding and analyzing the information. The results also show that observation and planning have a smaller role in this process. The high human error probability (HEP) operator was recorded at 0.99999 for the printing process and 0.99789 for handling dirty products. Both of these values indicate that the risk of human error in this operation is classified as very high.

The Poka-Yoke Method

To minimize human error and reduce product defects, it is essential to apply effective solutions. One of the proposed improvements that can be done is to design Standard Operating Procedures (SOP) which has just used the Poka-Yoke approach. Poka-yoke is a method designed to prevent errors that can cause product defects. In the context of printing, the application of ink sensors in the ink container will help operators to be more accurate in measuring and using the required ink, thereby reducing the risk of error in filling. In addition, better equipment and material arrangements will support a more efficient and standardized printing process.

The Benefits of Implementing the Cream and Poka-Yoke Approach

The implementation of the Cream and Poka-Yoke approach will have several benefits for the XXX printing unit. Firstly, it will help to reduce the frequency of human error and product defects. Secondly, it will increase consumer satisfaction by providing high-quality products. Finally, it will improve the overall efficiency of the production process by reducing the time and resources required to produce products.

Conclusion

In conclusion, the XXX printing unit is facing a significant problem with human error in the printing section. The Cream approach analysis results show that the two most dominant cognitive functions in the process of printing and handling dirty products are execution and interpretation. The high human error probability (HEP) operator was recorded at 0.99999 for the printing process and 0.99789 for handling dirty products. To minimize human error and reduce product defects, it is essential to apply effective solutions. The implementation of the Cream and Poka-Yoke approach will have several benefits for the XXX printing unit, including reducing the frequency of human error and product defects, increasing consumer satisfaction, and improving the overall efficiency of the production process.

Recommendations

Based on the analysis and results, the following recommendations are made:

Implement the Cream and Poka-Yoke approach: The XXX printing unit should implement the Cream and Poka-Yoke approach to identify and prevent human error in the printing section.
Design Standard Operating Procedures (SOP): The company should design SOP that includes clear and standard work procedures to reduce the risk of human error.
Improve equipment and material arrangements: The company should improve the equipment and material arrangements to support a more efficient and standardized printing process.
Train operators: The company should train operators on the new SOP and equipment to ensure that they are aware of the changes and can operate the equipment safely and efficiently.

Future Research Directions

Future research directions include:

Further analysis of human error: Further analysis of human error in the printing section to identify the root causes of the problem.
Development of new SOP: Development of new SOP that includes clear and standard work procedures to reduce the risk of human error.
Implementation of new equipment and material arrangements: Implementation of new equipment and material arrangements to support a more efficient and standardized printing process.
Evaluation of the effectiveness of the Cream and Poka-Yoke approach: Evaluation of the effectiveness of the Cream and Poka-Yoke approach in reducing human error and product defects.
Frequently Asked Questions (FAQs) about the Cream Approach and Poka-Yoke Method

Q: What is the Cream Approach?

A: The Cream Approach is a method designed to analyze human error and identify the cognitive functions that contribute to it. It is a tool used to understand the mental processes involved in human error and to identify the root causes of the problem.

Q: What is the Poka-Yoke Method?

A: The Poka-Yoke Method is a method designed to prevent errors that can cause product defects. It is a tool used to identify and prevent errors in the production process by designing and implementing standard operating procedures (SOP) and equipment arrangements that support a more efficient and standardized production process.

Q: How does the Cream Approach work?

A: The Cream Approach works by analyzing the cognitive functions involved in human error. It identifies the mental processes involved in human error and identifies the root causes of the problem. The approach is based on the idea that human error is often the result of a combination of factors, including cognitive biases, lack of training, and inadequate equipment and material arrangements.

Q: What are the benefits of using the Cream Approach and Poka-Yoke Method?

A: The benefits of using the Cream Approach and Poka-Yoke Method include:

Reduced frequency of human error and product defects
Increased consumer satisfaction
Improved overall efficiency of the production process
Reduced time and resources required to produce products
Improved quality of products

Q: How can the Cream Approach and Poka-Yoke Method be implemented in a production process?

A: The Cream Approach and Poka-Yoke Method can be implemented in a production process by:

Identifying the cognitive functions involved in human error
Designing and implementing standard operating procedures (SOP) that support a more efficient and standardized production process
Improving equipment and material arrangements to support a more efficient and standardized production process
Training operators on the new SOP and equipment to ensure that they are aware of the changes and can operate the equipment safely and efficiently

Q: What are some common mistakes that can be prevented using the Cream Approach and Poka-Yoke Method?

A: Some common mistakes that can be prevented using the Cream Approach and Poka-Yoke Method include:

Incorrect measurement of materials
Incorrect operation of equipment
Incorrect handling of products
Incorrect storage of products
Incorrect disposal of waste

Q: How can the Cream Approach and Poka-Yoke Method be used to improve product quality?

A: The Cream Approach and Poka-Yoke Method can be used to improve product quality by:

Identifying the root causes of product defects
Designing and implementing standard operating procedures (SOP) that support a more efficient and standardized production process
Improving equipment and material arrangements to support a more efficient and standardized production process
Training operators on the new SOP and equipment to ensure that they are aware of the changes and can operate the equipment safely and efficiently

Q: What are some common challenges that can be faced when implementing the Cream Approach and Poka-Yoke Method?

A: Some common challenges that can be faced when implementing the Cream Approach and Poka-Yoke Method include:

Resistance to change from operators
Lack of training and resources
Inadequate equipment and material arrangements
Inadequate SOP and procedures
Difficulty in identifying and addressing the root causes of human error

Q: How can the Cream Approach and Poka-Yoke Method be used to improve employee safety?

A: The Cream Approach and Poka-Yoke Method can be used to improve employee safety by:

Identifying the root causes of accidents and near-misses
Designing and implementing standard operating procedures (SOP) that support a more efficient and standardized production process
Improving equipment and material arrangements to support a more efficient and standardized production process
Training operators on the new SOP and equipment to ensure that they are aware of the changes and can operate the equipment safely and efficiently

Q: What are some common metrics that can be used to measure the effectiveness of the Cream Approach and Poka-Yoke Method?

A: Some common metrics that can be used to measure the effectiveness of the Cream Approach and Poka-Yoke Method include:

Reduction in frequency of human error and product defects
Improvement in product quality
Reduction in time and resources required to produce products
Improvement in overall efficiency of the production process
Reduction in accidents and near-misses.