Introduction_to_Poka_Yoke 防错技术培训和案例.ppt

,Poka-yokeandJidoka:ContinuousimprovementtoZeroQualityControl,IntroductiontoPokaYoke,QualityandHumanError,“Toerrishuman”AlexanderPopeHumanbeingsmakemistakes,humanbeingssometimesforget.Ifyourelyonahumanbeingtoproducequalityproductandnotmakeamistakeornotforgetsometimes.Thenyoureallydonotcaretomakeaqualityproduct.ADDRESSQUALITYISSUESTHROUGHTHEPROCESS.,EvolutionofKey“Lean”Concepts,1945:JustInTime,1948:Pull:Withrawalbysubsequentprocesses,1953:“Supermarket”systems,1947:Dualmachinehandling,“L”shapedlayout,1953:Workcellsin“U”shapedlayouts,1950:Multi(3-4)machinehandling,rectangularor“U”shapedlayout,1955:Waterspiderconcept,1962:Kanban,companywide,internal,1965:Kanban,externalsuppliers,1950:Andon,visualcontrol,Set-upreduction:internaldoesnotdependonanoperatororassembler.Hasahighcapabilityofachievingzerodefects.Machinestopswhenanirregularityisdetected,WARNINGAPPROACHSometimesanautomaticshutoffsystemisnotanoption.Awarningoralarmsystemcanbeusedtogetanoperatorsattention.Belowleftisanexampleofanalarmsystemusingdials,lightsandsoundstobringattentiontotheproblem.Colorcodingisalsoaneffectivenonautomaticoption.,Poka-yokeandJidoka,InspectionMethod,SourceInspectionPoka-yoke-Proactive,InformativeInspection(successive)Jidoka-Reactive,InformativeInspection(self)Jidoka-Reactive,SettingFunction,RegulativeFunction,CommonMistakeproofingDevices,GuidePinsBlinkinglightsandalarmsLimitswitchesProximityswitchesCountersChecklists,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,MethodsforUsingPokayoke,Pokayokesystemsconsistofthreeprimarymethods:1.Contact2.Counting3.Motion-SequenceEachmethodcanbeusedinacontrolsystemorawarningsystem.Eachmethodusesadifferentprocesspreventionapproachfordealingwithirregularities.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Missingcylinder;pistonfullyextended,alarmsounds,ContactMethodusinglimitswitchesidentifiesmissingcylinder.,Cannotproceedtonextstep.,Cylinderpresent,ContactMethod,Acontactmethodfunctionsbydetectingwhetherasensingdevicemakescontactwithapartorobjectwithintheprocess.Anexampleofaphysicalcontactmethodislimitswitchesthatarepressedwhencylindersaredrivenintoapiston.Theswitchesareconnectedtopistonsthatholdthepartinplace.Inthisexample,acylinderismissingandthepartisnotreleasedtothenextprocess.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,LimitSwitches,ToggleSwitches,PhysicalContactDevices,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Light,Transmitter,Receiver,Object,EnergyContactDevices,Photoelectricswitchescanbeusedwithobjectsthataretranslucentortransparentdependingupontheneed.Transmissionmethod:twounits,onetotransmitlight,theothertoreceive.Reflectingmethod:PEsensorrespondstolightreflectedfromobjecttodetectpresence.Ifobjectbreaksthetransmission,themachineissignaledtoshutdown.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,ContactDevice,Anexampleofacontactdeviceusingalimitswitch.Inthiscasetheswitchmakescontactwithametalbarbsensingitspresence.Ifnocontactismadetheprocesswillshutdown.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,ContactMethods,Donothavetobehightech!Passivedevicesaresometimesthebestmethod.ThesecanbeassimpleasguidepinsorblocksthatdonotallowpartstobeseatedinthewrongpositionpriortoprocessingTakeadvantageofpartsdesignedwithanunevenshape!Aworkpiecewithaholeabumporanunevenendisaperfectcandidateforapassivejig.Thismethodsignalstotheoperatorrightawaythatthepartisnotinproperposition.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,CountingMethod,Usedwhenafixednumberofoperationsarerequiredwithinaprocess,orwhenaproducthasafixednumberofpartsthatareattachedtoit.Asensorcountsthenumberoftimesapartisusedoraprocessiscompletedandreleasesthepartonlywhentherightcountisreached.Anotherapproachistocountthenumberofpartsorcomponentsrequiredtocompleteanoperationinadvance.Ifoperatorsfindpartsleftoverusingthismethod,theywillknowthatsomethinghasbeenomittedfromtheprocess.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Motion-SequenceMethod,Thethirdpokayokemethodusessensorstodetermineifamotionorastepinaprocesshasoccurred.Ifthestephasnotoccurredorhasoccurredoutofsequence,thesensorsignalsatimerorotherdevicetostopthemachineandsignaltheoperator.,Thismethodusessensorsandphoto-electricdevicesconnectedtoatimer.Ifmovementdoesnotoccurwhenrequired,theswitchsignalstostoptheprocessorwarntheoperator.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,IndicatorBoard,Machine,Motion-SequenceMethod,Inordertohelpoperatorsselecttherightpartsfortherightstepinaprocessthe“sequencing”aspectofthemotion-stepmethodisused.Thisisespeciallyhelpfulwhenusingmultiplepartsthataresimilarinsizeandshape.Inthisexample,eachstepofthemachinecycleiswiredtoanindicatorboardandatimer.Ifeachcycleofthemachineisnotperformedwithintherequired“time”and“sequence”,theindicatorlightforthatstepwillbeturnedonandthemachinewillstop.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,TypesofSensingDevices,Sensingdevicesthataretraditionallyusedinpokayokesystemscanbedividedintothreecategories:1.Physicalcontactdevices2.Energysensingdevices3.WarningSensorsEachcategoryofsensorsincludesabroadrangeofdevicesthatcanbeuseddependingontheprocess.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Devices:PhysicalContactSensors,Thesedevicesworkbyphysicallytouchingsomething.Thiscanbeamachinepartoranactualpiecebeingmanufactured.Inmostcasesthesedevicessendanelectronicsignalwhentheyaretouched.Dependingontheprocess,thissignalcanshutdowntheoperationorgiveanoperatorawarningsignal.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Device:TouchSwitchMethod:Contact,Usedtophysicallydetectthepresenceorabsenceofanobjectoritem-preventsmissingparts.Usedtophysicallydetecttheheightofapartordimension.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,Devices:EnergySensors,Fiberoptic,Photoelectric,Vibration,Thesedevicesworkbyusingenergytodetectwhetherornotandefecthasoccurred.,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,WarningSensors,ColorCode,Lights,Warningsensorssignaltheoperatorthatthereisaproblem.Thesesensorsusecolors,alarms,lightstogettheworkersattention!Lights:Thesesensorsmaybeusedinconjunctionwithacontactorenergysensortogettheoperatorsattention.,LightsconnectedtoMicroswitches&timers,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,3RulesofPOKAYOKE,DontwaitfortheperfectPOKAYOKE.Doitnow!IfyourPOKAYOKEideahasbetterthan50%chancetosucceedDoit!Doitnow.improvelater!,*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence,PokaYokeExercise#1-Problem,MatsushitaElectric:IndustrialWashingMachineDivisionCorrectwaterleveliscriticaltothepackage-sealingmachine.Operatorvisuallycheckswaterlevel4Xpershift.Instancesofinadequatewaterlevelshaveoccurred.,Whatwouldyoudo?,PokaYokeExercise#1-Solution,MatsushitaElectric:IndustrialWashingMachineDivisionInadequatewatervolumeactivatesawaterlevelsensorandavalveopensautomaticallytosupplywater.Approximatecost:$150,PokaYokeExercise2-Problem,AsahiNationalLightingCompanyTheupperandlower“boxers”stapletheboxclosed.Occasionallythebottomstapler“misses”.Sincecasescontinuetomovealongtheline,itisespeciallydifficulttoverifythepresenceofastapleonthebottomofthebox.,Whatwouldyoudo?,PokaYokeExercise2-Solution,AsahiNationalLightingCompanyAsensortodetectstapleswasmountedattherearofthepackagingmachine.Thissensor,linkedtoacounter,verifiesthenumberofstaplesandsendsasignaltothe“stopper”tostopthecasesifastapleismissed.,PokaYokeExercise3-Problem,AsakawaAutoBodyIndustriesInatwostepprocess,workerswouldfirstdrillholesinaboardset,thentaketheboardsetandspotweldit.Occasionallytheoperatorswouldforgettodrillalloftheholesrequired.Afterspotwelding,thepiececouldnotbereworkedifitwasmissingholes.,Flow,Whatwouldyoudo?,PokaYokeExercise3-Solution,AsakawaAutoBodyIndustriesThewelderanddrillwerelinked.Simpleholesensorswereinstalledonthedrillmachine.Thespotwelderwouldnotoperateunlessallholesweredetected.,Flow,ShigeoShingo,ZeroQualityControl:SourceInspectionandthePoka-yokeSystem,ShingoQuiz,1.WhichofthefollowingisnotoneoftheinspectiontechniquesidentifiedbyShingo:A.SourceB.InformativeC.StatisticalD.Judgment2.JudgmentInspection:A.isaveryeffectiveinspectiontechniqueB.reducesdefectratesdramaticallyC.usedsolelytodiscoverdefectsafterproductionD.shouldbeusedwheneverpossible,ShingoQuiz,3.Asettingfunction:A.isaveryeffectiveinspectiontechniqueB.signalsthatadefecthasoccurredC.keepsamachinefromoperatingwhendefectsarelikelytobeproducedD.isthelinkbetweeninspectionandtheregulatoryfunction4.Aregulatoryfunction:A.istheremedialactiontakenafteraprocessgoesout-of-controlB.signalsthatadefecthasoccurredC.keepsamachinefromoperatingwhendefectsarelikelytobeproducedD.BorC,ShingoQuiz,5.SourceInspection:A.reducesdefectratesdramaticallyB.usedsolelytosortoutdefectsafterproductionC.shouldbeavoidedD.bothA&B6.Whichisnotaninformativeinspectiontechnique:A.statisticalprocesscontrolB.acceptancesamplingC.successive-checksD.self-checks,ShingoQuiz,7.ThecorrectrankingofShingosinspectiontechniques(frombesttoworst)is:A.judgment,informative,sourceB.source,judgment,informativeC.informative,source,judgmentD.source,informative,judgment8.InformativeInspection:A.inspectsproductstohelpcontroltheprocessB.inspectsprocesstohelpcontroltheproductC.keepsamachinefromoperatingwhendefectsarelikelytobeproducedD.shouldbeavoided,ShingoQuiz,9.Poka-Yoke:A.replacesanyqualitysystemyouarecurrentlyusingB.canreduceoreliminatehumanerrorC.cannotbeusedtoreduceprocessvarianceD.isonlyusedforsourceinspection,ShingoQuiz,1.WhichofthefollowingisnotoneoftheinspectiontechniquesidentifiedbyShingo:A.SourceB.InformativeC.StatisticalD.Judgment2.JudgmentInspection:A.isaveryeffectiveinspectiontechniqueB.reducesdefectratesdramaticallyC.usedsolelytodiscoverdefectsafterproductionD.shouldbeusedwheneverpossible,C:Shingoidentified3inspectiontechniques:judgement,informative,source,C:Isusedsolelytodiscoverdefectsafterproduction.,ShingoQuiz,3.Asettingfunction:A.isaveryeffectiveinspectiontechniqueB.signalsthatadefecthasoccurredC.keepsamachinefromoperatingwhendefectsarelikelytobeproducedD.isthelinkbetweeninspectionandtheregulatoryfunction4.Aregulatoryfunction:A.istheremedialactiontakenafteraprocessgoesout-of-controlB.signalsthatadefecthasoccurredC.keepsamachinefromoperatingwhendefectsarelikelytobeproducedD.BorC,D:Asettingfunctiondetectswhentheinspectionoutcomeisnotacceptableandinvokestheregulatoryfunction,D:Aregulatoryfunctionisanattention-gettingsignal(abuzzer,warninglightormachinestoppage)thatsomethingiswrong.Itcanindicateadefecthasjustbeenmade(inself-checks)orthatitisabouttobemade(insourceinspections).,ShingoQuiz,5.SourceInspection:A.reducesdefectratesdramaticallyB.usedsolelytosortoutdefectsafterproductionC.shouldbeavoidedD.bothA&B6.Whichisnotaninformativeinspectiontechnique:A.statisticalprocesscontrolB.acceptancesamplingC.successive-checksD.self-checks,A:Sourceinspectioncheckstheprocessforcorrectoperatingconditionsbeforeproductionoccurs.Theknowncausesofdefectsareeithereliminatedorcorrectedbeforeproductioncancreatedefects.,B:Successive-ch