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46 DESIGN007 MAGAZINE I APRIL 2023 Engineering controls to error-proof (Poka- Yoke) safety standards can be utilized to attain a higher level of safety and decrease the proba- bilities of injuries. Common examples of error- proofing in manufacturing include: • Interlock door switches on machine doors, so the machine will not run with the door open • Using a self-retractable box knife which automatically retracts the knife when not in use • Fixing uneven production floors to avoid slips, trips, and falls Chemical processes play a big role in PCB manufacturing, and establishing exceptional standards for proper use of personal protective equipment (PPE) can improve the safety of a working environment. Goggles, face shields, aprons, gloves, and chemical boots are com- mon forms of PPE used on the production floor. When choosing PPE equipment, manu- facturers should make sure it is impermeable to the chemicals being used. Ongoing training of both new and current employees is perhaps the most important aspect of ensuring safety on the production floor. Training should be diverse and compre- hensive, covering everything from proper li- ing techniques to electrical safety. Quality Quality is about more than quality products. It should be top of mind with respect to every aspect of production. e quality cycle really begins with process development and evalu- ation. Manufacturers need to scrutinize pro- duction output data in search of process vari- ances. is will help to determine where in the manufacturing cycle process that quality out- put meets or exceeds expectations. ere are several tools available to control production quality. ey include: • DMAIC (Define, Measure, Analyze, Improve, and Control) refers to a five-step, data-driven improvement cycle aimed at improving, optimizing, and stabilizing operational processes • SPC (Statistical Process Control) is a quality control method used by manufac- turers to maximize efficiency and minimize waste • FMEA (Failure Mode and Effects Analysis) can be employed to create a known production quality output Quality does not begin and end with the production process. It should be embedded in the organization's culture and a priority for everything from the overall customer experi- ence to individual elements of employee rela- tions such as training or incentive programs. On-Time Delivery Quality products do not arrive late. e first thing customers ask during the quote process is oen, "When can I expect delivery?" PCB man- ufacturers are oen among the most mission- critical supply chain components for producers of electronic products. is means manufactur- ers must understand with great accuracy every component of their production process before committing to a shipping due date. Every manufacturer strives for perfection, 100% on-time, all the time. If an organiza- tion is not at 100%, improvement is possible. To ensure on-time delivery, manufacturers should focus on the following: • Process the order correctly the first time. Customers won't wait for a supplier to build an order twice. • Know the capacity limitations of the facility. Correlate capacity level to the volume and timing of customer orders, paying particu- lar attention to where the largest constraints are located in the production process. • Continuously learn to overcome process- ing challenges using root cause analysis. is will make order processing less variable, more predictive, and less con- strained.