Abstract
When a product quality problem happens on the manufacturing line,it is usually determined that other hidden incidents take place which lead up to the onset of the problem. If it is possible to report every incident to the manager, then countermeasures can be taken to prevent the problem, as applied in Hinrichi's law. However, these incidents are not reported, so managers cannot take preventive action. In this paper, focus is placed on the prevention of unintended errors caused by workers. Cause of disturbing three step process to help prevent undesired quality problems is investigated. The three steps are firstly, the worker notices an error or incident. Secondly, the worker reports the incident to the manager, and thirdly, the manager accepts the report. Based upon this investigation, a 2-phase workshop is proposed to pursue the mental change of workers, consisting of a first phase workshop to analyze the cause of the social accidents and a second phase workshop to analyze the cause of the problems that happened on the local manufacturing line.
After the workshop,the number of incident reports from workers had increased,the management issues also increased, resulting in management action taken to solve the issues.
