How Does Human Errors Impact Long Term Growth of Manufacturing Businesses.pdf

Every improvement in your standard work can cut error-related downtime and boost throughput—without pointing fingers at anyone. In this brief guide, you’ll see:

• The most common process gaps that lead to mistakes
• Simple checks you can embed today
• How tighter workflows compound into long-term gains

Equip your leadership team with the insights they need—download for free today:

1. Strategies for Minimizing Human Errors....
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How Does Human Errors
Impact Long Term Growth
of Manufacturing
Businesses?
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2. 23% of unplanned downtime in
factories is caused by human error,
resulting in significant financial
losses for manufacturers globally.
DID YOU KNOW?
23%
40% of quality issues in manufacturing
are linked to manual errors, which
often stem from miscommunication
and lack of standardized procedures.
40%
92% of executives believe human error
is still a top risk in their production
processes despite automation
advancements.
92%
Human error accounts for 80% of
workplace accidents, many of which
could be avoided with better training
and procedures in place.
80%
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3. What is Human Error in Manufacturing?
Human error in manufacturing isn’t just about someone pressing the wrong button or
overlooking a step. It's much broader and includes various scenarios that can lead to
inefficiencies, poor product quality & even safety risks.
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4. Operational mistakes:
Forgetting or skipping a step
during production.
Manual input errors:
Incorrectly entering data or
measurements.
Miscommunication:
Incomplete or misunderstood
instructions between teams.
Fatigue-related mistakes:
Errors caused by physical or
mental exhaustion.
Machine malfunctions:
Failures due to equipment
breakdowns or technical faults.
Supplier defects:
Receiving poor-quality materials
from vendors.
Software bugs:
Errors caused by faulty software or
programming issues.
Environmental disruptions:
Unexpected power outages or natural
disasters impacting production.
Considered Human Error Not Considered Human Error
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5. SWP
How Deeply Human Error Impacts Manufacturing Businesses?
Errors also lead to 33% of quality issues (ASQ),
causing product defects, waste, and expensive
recalls that hurt reputation & customer trust.
Human errors contribute to $10 billion in global
manufacturing losses annually, adding to
operational costs & long-term financial strain.
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6. Strategies to Minimize
Human Errors in
Manufacturing
To minimize human errors, lean
manufacturing techniques offer
practical and proven solutions.
Here are 5 advanced strategies that
reduce errors, improve efficiency,
and enhance overall operations.
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7. 1. Kaizen (Continuous Improvement)
“Kaizen can improve productivity by
up to 30% through continuous small
improvements.”
Kaizen promotes ongoing, incremental
improvements in processes through employee
involvement at all levels.
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8. Kaizen
Error Reduction
What to Expect After
Implementation?
Improved Efficiency
Greater Employee
Ownership over Quality
Operators suggest small process
tweaks, such as:
reorganizing tools for easier
access,
reducing unnecessary
movements during assembly.
How to Implement Kaizen?
Setup daily 10-minute improvement meeting
Operator
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9. Kaizen
Error Reduction
How to Implement Kaizen?
Encourage daily improvements by fostering a
culture where employees identify and act on
inefficiencies. Conduct regular improvement
meetings and set up a feedback system.
Improved Efficiency
Greater Employee
Ownership over Quality
OR
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10. 2. Poka-Yoke (Error Proofing)
“Poka-Yoke techniques can reduce
defect rates by as much as 90% in
repetitive tasks.”
Poka-Yoke involves designing systems or
processes to prevent mistakes or make errors
immediately detectable.
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11. Reduction in
recurring errors
What to Expect After
Implementation?
Higher quality
control
Trigger an alarm if:
the box is incorrectly sealed,
unusual activity is detected or
speed is slowed
allowing operators to fix it before
continuing.
How to Implement Poka-Yoke?
Install sensors on
a packaging line
Sensor
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12. 3. Jidoka (Automation with
Human Oversight)
“Jidoka can lead to a 40% reduction
in downtime and defective
products.”
Jidoka ensures that machines stop
automatically when a problem occurs, allowing
humans to address the issue before it worsens.
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13. Fewer defective
products
What to Expect After
Implementation?
Quicker identification
of process issues
T
r
a
c
k
ing p
r
o
d
u
c
t
i
o
n

l
i
n
e
How to Implement Jidoka?
Install sensors on
a packaging line
Fault Sensor
Better overall quality
management
For preventing defective
items from progressing
further
Stops production line,
when a component is not
aligned correctly.
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14. 4. Cross-Training and Job
Rotation
“Cross-training employees can
reduce error rates by up to 25% due
to increased versatility.”
Ensuring employees are skilled in multiple roles
reduces errors caused by fatigue or lack of
expertise in any one position.
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15. Lower error rates due to
improved skill diversity
What to Expect After
Implementation?
b=Better adaptability in
the workforce
How to Implement Cross-
Training and Job Rotation?
Training assembly
line workers
Practical
operational training
Competitive performance
& high retention
Training them to
operate different
machines
Rotate roles weekly to
reduce strain and
maintain high focus,
ensuring fewer errors
from monotony.
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16. 5. Standard Work Instructions
(Visual Work Instructions)
“Standard Work Instructions can cut
errors by 50% through clearer
communication & consistent processes.”
Standard work instructions provide clear, step-
by-step visual guides for operators, reducing
ambiguity and confusion during processes.
DID YOU KNOW?
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17. Lower error rates due to
improved skill diversity
What to Expect After
Implementation?
b=Better adaptability in
the workforce
How to Implement Standard
Work Instructions?
Create digital work instruction for
implementing standard work
Standard Work Pro
Competitive performance
& high retention
Create visual guides showing
step-by-step tasks with images
and clear instructions at each
station, ensuring all operators
follow the same process.
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18. Standard Work is critical because clear, visual job instructions eliminate guesswork
and help standardize tasks, minimizing human error significantly across the board.
So, which is the best one?
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19. How to Build Clear Work Instructions
to Avoid Human Errors?
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20. SWP
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Use images, diagrams, and flowcharts that visually explain each step of the
process. Stick to a standardized format so that operators recognize the
structure and layout every time.
Example
A production line assembling electronic
components might include a step-by-
step diagram showing how to place
each part on the circuit board, using
color-coded arrows & labels to indicate
the correct orientation.
1. Use Visuals & Standardized Formats

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Simplify complex processes by dividing them into smaller, manageable steps.
Ensure each instruction is actionable & leaves no room for misinterpretation.
Example
Instead of a single step reading,
“Assemble the motor,” break it down into
smaller steps: (1) Place the motor into
the housing, (2) Align the mounting
holes, (3) Tighten screws to 10 Nm
torque.
2. Break Down Tasks into Simple Steps

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Allow operators to provide input on the clarity of instructions, and make
adjustments based on their feedback to prevent recurring errors.
Example
After implementing new instructions for
packaging, operators report confusion
about where to place inspection labels.
By adding a clear diagram, the issue is
resolved, and errors related to missing
labels are reduced.
3. Incorporate Feedback Loops

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Embed safety and quality reminders at critical points in the instructions to
prevent injuries and defects.
Example
For a step that involves using a cutting
machine, include a visual reminder to
wear safety gloves and ensure the blade
guard is properly positioned before
cutting. This reduces the risk of
accidents and ensures product safety.
4. Include Safety and Quality Checks

24. SWP
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Periodically review and test the work instructions to ensure they reflect current
best practices and account for any process changes.
Example
After introducing a new model of
equipment in the assembly line, test the
work instructions with a few operators.
Update the instructions to reflect
changes in tool usage or assembly
techniques based on the feedback
gathered during the trial phase.
5. Test and Update Regularly

25. Get in touch with us today
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can improve your Operational performance?