A study of world class manufacturing training methodologies on human errors

The main purpose of the thesis is to address the errors happening in the Automotive Industry. To be specific, the thesis deals with the adverse effects caused by the human errors in the assembly line. The increasing number of parts variants, working environment and the capability of the individual employee are some of the causes of human errors in the assembly line. A qualitative study has been made in FCA about the human errors and the data has been analysed. Then the root cause of the same has been identified and different methodologies to eradicate the human errors has been suggested. Three type of methodologies has been proposed. First (Innovative) methodology, Grouping and Sequencing helps in avoiding the mismatch of the product variants by categorization of the parts and Memory Game helps in improvising the human memory and to remember the parts. Second (Improvising) methodology, Poka Yoke has been suggested for the model area in the plant and Quality Gate should be at the end of each workstation to make the concerned employee responsible for his own mistakes. Third (Digital) methodology, Light Guide System, which guides the employee in each stage of the entire assembly process. The thesis thereby concludes with the proposal of best training methodologies so as to avoid the human errors in FCA. The above suggested methodologies would improvise the performance of the employee and avoid making mistakes. Initially the employees would be trained in the FCA - WCM Academy, then within the plant.