Build a mini-FMEA for a look-alike risk

Two look-alike cartons sit in adjacent shelf zones. A technician selected the wrong carton, but final verification caught it. Use FMEA to move from visible risk to stronger barrier: failure mode, effect, current control, better control, review. Common trap: adding a warning sticker and calling it fixed. Stickers can help, but if the failure happens during speed, fatigue, or interruption, another attention-dependent cue may not change the underlying selection path. Failure mode Wrong carton selected during stock pick because two packages look similar and sit close together. A failure mode is the specific way the process can fail, not a…

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