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🏭 Human Error in Manufacturing: The Silent Killer of Productivity 🔄

Did you know? 70% of losses in manufacturing come from human error! But here’s the truth—human error is not the root cause. It’s a symptom.

The biggest mistake companies make? Blaming workers instead of fixing the system.

💡 WCM shows that human error isn’t about "laziness" or "not paying attention." — it happens due to:

🔍 1. Competence Issues
✔ Lack of training, unclear procedures, poor leadership.
✔ Employees unaware of standards, skills gaps.

🔍 2. Behavioral Factors
✔ Overconfidence, resistance to procedures.
✔ Absent-mindedness, stress, shortcuts.

🔍 3. Personal Conditions
✔ Health issues, personal/family stress.

🔍 4. System Failures
✔ No SOPs, poor communication.
✔ Wrong tools, poor maintenance, bad ergonomics.
✔ Disorganized workplace, poor lighting, unclear signage.

💡 Fix the system, and human errors disappear! But how?

🔍 Human Error RCA – The Right Way
Instead of blaming employees, we partner with them to understand why errors happen. Here’s how:

🔹 Putting Employees at Ease
✔ Explain the process in a non-threatening way – The goal is improvement, not punishment.
✔ Emphasize teamwork – "We have an issue that we will solve together."
✔ Remove formality – Keep the conversation natural to encourage honesty and open discussion.

🔹 Asking the Right Questions

1️⃣ BEFORE the task
❓ How do you do this task?
✅ Checks existing procedures, training, and knowledge

2️⃣ DURING the task
❓ How do you know you’re doing it correctly?
✅ Looks at visual management, feedback loops, and verification

3️⃣ AFTER the task
❓ How do you know the outcome is defect-free?
✅ Ensures there is a clear way to confirm success

4️⃣ What if something goes wrong?
❓ What would you do if you find a problem?
✅ Measures problem-solving knowledge and escalation process

Turning Human Error into Opportunity
💡 Instead of blaming, we redesign systems to make errors impossible.
💡 Instead of punishing, we train, coach, and improve workplace conditions.
💡 Instead of reacting, we prevent errors before they happen.
This is Lean & WCM thinking—shifting from firefighting to error-proofing.

🎯 Your Turn!
👉 Have you seen human error in your workplace?
👉 What strategies work for reducing errors?

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