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Putting people and tools on the line to catch defects created by another process is a sign of not showing respect in the inherent capability of the people to do good work. Instead, management has to spend time and energy in creating processes that are capable and can catch errors and mistakes by themselves leading to continuous improvement. Dr. Shigeo Shingo preached these concepts when he talked about zero quality control. According to Dr. Shingo, we cannot achieve the aim of zero defects until we make each element of the process capable to produce perfect quality by ensuring the errors and mistakes are quickly identified and corrected before they lead to defects. His idea of poka-yoke and source checking are exactly in line with this principle.

How could we avoid this from happening with our cross check process?

Let's set it as a vision and then design in 6-8 month improvement targets. The vision can be a year or two out and we can steadily march toward the vision with incremental targets.

Zero defects is a philosophy of Lean. It simply means that every process should be designed so that it is impossible to produce poor quality. The underlying premise, which is true in nearly every case, is that the cost of preventing problems is lower than the cost of fixing them.

Just a good, basic article on zero defects

5S is a process and method for creating and maintaining an organized, clean, and high performance workplace.  It enables anyone to distinguish between normal and abnormal conditions at a glance.  5S can be the foundation for continuous improvement, zero defects, cost reductions and a more productive work space.  The 5S methodology is a systematic way to improve the workplace, processes and products through employee involvement.