精益生产防错

1、Error Proofing防错Topics - Error Proofing TrainingTopics主题Objectives of the Training培训的目的What and Why of Error Proofing什么是防错，怎样进展防错Application of Error Proofing防错运用Identify Opportunities for Errors防错时机确实定Overview of Failure Mode and Effects Analysis (FMEA)失效方式和效果分析总括Error Proofing Options防错的选择Preventi

2、on & Detection Through Poka Yoke Devices经过Poka Yoke进展预防与探测Move to The Next Level转入下一级A Benchmark Within Eaton伊顿内部规范Summary概要Objectives of the Training培训的目的Understand What Is Error Proofing and What It Can Do了解什么是防错和防错能做什么Understand the Principles of Error Proofing了解防错的原理Learn How to Apply Error Proo

3、fing to Products and Processes了解怎样对产品及工艺过程运用防错Learn About the Poka Yoke Devices and Systems了解Poka Yoke安装和系统Learn the Process of Implementation and Continuous Improvements了解实施防错的过程和继续改良的过程What Are Your Expectations?他们的期望是什么？What and Why of Error Proofing什么是防错以及为什么要防错Definition定义Error Proofing Is a Sy

4、stematic Approach for Anticipating and Detecting Potential Defects and Preventing Them From Reaching the Customer(Internal or External)防错是一种预测及探测潜在缺陷以及阻止缺陷影响客户的体系方法(内部防错和外部防错)Error Proofing by Other Names以其他称号进展防错Fool Proofing防止愚笨行为Idiot Proofing防止白痴行为Mistake Proofing防止错误行为Fail Safing平安失效Poka YokeZe

5、ro Quality Control (Zero Defects)零质量控制零缺陷Design for Manufacture and Assembly制造和装配的设计Let Us Not Argue the Merits of These NamesLet Us Decide What We Want to Achieve我们不要争论这些称号,让我们决议想要完成什么?Demoralizing Terms防错术语Characteristics of Error Proofing防错的特点Proactive Identification and Prevention前期识别及预防Prevent

6、First首先进展防错Do Not Allow Defect From Going Further其次不准许缺陷进一步开展Intentionally Designed, Not Happenstance设计错误,非偶尔错误.At the Source - Close to the Origination 错误的来源_接近发源地.Inexpensive First 首先本钱不高Transparent to the Operator 操作者很容易发现Absolutely Reliable 错误根源查找绝对准确A Means to Achieve Zero Defect Product一种到达0缺陷

7、产品的方法Defects in Products Are the Imperfections (or Faults, or Flaws, or Blemishes, or Shortcomings, or Failings, or Deficiencies) 缺陷是指产品里的不完好性(或者缺点,或者裂纹,或者瑕疵，或者短处，或者过失，或者缺乏)Resulting From Errors错误产生的结果Errors Are Human Oversights (or Faults, or Blunders, or Boo-boos, or Slip-ups, or Inaccuracies or M

8、iscalculations) That Cause Defects in Products错误是人为忽略(或者过错,或者失误,或者低级错误，或者失败，或者精度失误或者计算失误)，这些引起产品的缺陷。Defects and Errors 缺陷和错误SO, Errors Cause Defective Products!所以,错误导致有缺陷的产品产生!Why Are Errors Made为什么会导致错误Any Product Is a Result of Numerous Decisions Made and Actions Taken by Human Beings, During:任何产品

9、都可以在下述一系列人为行为中产生错误：Product Design产品设计Process Design过程设计Equipment Design设备设计Component Fabrication Processes零件加工过程Product Assembly Processes产品装配过程Inspection Processes检验过程Paperwork Generation程序行程过程Etc.等等And Human Beings are Fallible or Imperfect人是容易犯错或不完美的SOME Examples of Defects属于缺陷的一些例子Wrong or Inapp

10、ropriate Material错误或不适宜的资料Wrong or Non-functioning Components错误或者没有功能的零件Wrong Dimensions or Tolerances尺寸或公过失误Missing Components零件漏装Foreign Matters, Contamination杂质物质,污秽物Damaged Product or Components受损产品或零件Wrong Paperwork, or Wrong Product Shipped程序错误或者运输了错误的产品Non-functioning or Malfunctioning Produc

11、t没有功能的产品或者是缺点产品Wrong Shipping, or Wrong Billing运输错误或者是填单错误SOME Examples of Causes of Defects导致缺陷的一些例子Poor Design Decisions设计比较乏味Omitted or Wrong Processing过程忽略或过程错误Missing / Extra Parts or Wrong Parts漏装/多装了错误的零件Omitted or Wrong Adjustment / Testing 脱漏调整/测试或调整/测试过程错误Wrong Equipment Setup or Loss of S

12、etup设备设置错误或没有进展设备设置Wrong Material, Components or Assemblies资料，零件或者装配错误Wrong Communication, Instructions, Procedures, or Methods错误的信息，指令，程序，或者方法Inexperience, Lack of Training, Wrong Training, Lack of Retraining缺乏阅历，缺乏培训，培训错误，短少再培训SOME Examples of Results of Defects缺陷导致的结果例如Malfunction or Non-function

13、ing Product有缺点或者缺乏机能的产品Inconvenience, Discomfort, Injury, Death费事，不便，损伤，死亡Delays, Cancellations延期，取消Financial Losses财政损失Loss of Use or Productivity成效或者消费力的缺乏Damage to Customers Property损害客户的利益Liabilities and Law Suites负债和法律问题Loss of Reputation and Business声誉和业务受损SOME Causes of Human Errors导致人们犯错误的一些

14、缘由Forgetfulness, Loss of Concentration, Lack of Attention or Diverted Attention健忘，不集中，缺乏留意力或者转移留意力Misunderstanding or Lack of Understanding误解或者缺乏了解Lack of or Improper Experience / Training缺乏阅历/培训或者不正确的阅历/培训Lack of Standardization缺乏规范Intentional or Willful Error有意图的或者恶意的错误Wrong or Delayed Decision决议错

15、误或拖延Limited or Lack of Sensory Capability (e.g., Smell, Color, Touch)有限的或者没有感官才干例如，嗅觉，颜色，触觉Lack of Application of Common Sense缺乏运用常识判别的才干Error Proofing in a Few Words预防错误的一些方法“ occurrence of defect was the result of some condition or action, and that it would be possible to eliminate defects entirel

16、y by pursuing the cause. The causes of defects lie in worker errors, and defects are the results of neglecting those errors. It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.缺陷的产生是一些环境或者行为导致的结果，但是完全有能够经过查找缘由排除缺陷。缺陷缘由在于工人，缺陷是由于工人忽视错误而产生的。假设

17、工人能及时的发现错误并且消除错误，就不会导致缺陷的产生。Shigeo ShingoWhy Error Proof?为什么防错？99.9% Error Free Could Result in 99.9%没有错误导致什么结果2,000,000 Documents Lost by IRS IRS短少2，000，000档案16,000 Pieces of Mail Lost Every Day 每天丧失16，000邮件22,000 Wrongly Debited / Credited Checks Per Hour每个小时都会发生22，000写错借方和贷方的支票1,314 Wrongly Conne

18、cted Phone Calls Per Minute每个小时都会发生1，314起占线20,000 Incorrect Drug Prescriptions Per Year每个小时都会发生20，000起用错药物的情况12 Newborn Babies Given to Wrong Parents12个小孩被父母抱错2 Unsafe Landings Every Day at OHare Airport每天都会有2起飞机不平安着陆32,000 Missed Heartbeats Per Person Each Year每年每个人都会有32，000Is 99.9% Good Enough? 99

19、.9% 够不够好?The Errors That Became Headlines错误变成头条Titanic Sinking泰坦尼克号的沉没Challenger Booster Rocket Seal Failure挑战者号火箭发射失败Mars Landing Module Crash火星升空失败坠毁Hubbell Telescope Reflector ErrorHubbell望远镜反射误差Exxon Valdez Oil SpillExxon Valdez 石油泄露Chernobyl Nuclear Power Plant MeltdownChernobyl Nuclear Power 设

20、备报废Release of Methyl Isocyanate (MIC) From Union Carbide Plant in Bhopal, India甲基异丙酮从Bhopal, India ,MIC碳化物厂房泄露Three Mile Island Nuclear Plant 三英里小岛的核厂房Firestone Tires on Ford Explorer福特车上的耐火石探测器Error Proofing and Lean防错及精益消费Lean Insists on One Piece Flow精益消费强调单件流If That One Piece Is Defective, Flow

21、Is Disrupte假设单件流有缺陷,流向就会被打断Lean Insists on Limited Inventory精益消费强调有限库存 If That Inventory Is Defective, the Lines Can Sto假设库存有缺陷,线路就会停顿Lean Means Eliminating Waste精益是指消除浪费Defects and Corrective Actions Are Wast缺陷以及纠正措施是针对浪费Lean Requires That Equipment Is Ready When Needed and Functions Well As Long A

22、s Necessary精益消费要求当需求设备时,设备马上可以用,且功能完好Error Proofing the Tools, Fixtures, Setups, Methods and Documents Ensures Equipment Effectiveness 刀具,卡具,启动,方法以及文件等防错以确保设备的有效性Error Proofing Examples in Everyday Life在每天生活中防错的一些例子Home家里Automatic Shutoff Irons全自动熨斗Ground Fault Circuit Breakers for Bathroom or Outdo

23、or Electric Circuits浴室或室外电气线路的接地维护Pilotless Gas Ranges and Hot Water Heaters油量表以及热水器Child-Proof Caps on Medicine Bottles药瓶上维护小孩平安的瓶盖Retail零售Tamper-Proof Packaging锥型防错包装Bar Coding at Checkou检验时的条码Office办公室Spell Check in Word Processing Software在 Word word处置软件中进展拼写检查Verifying “Do you want to delete? W

24、hen Press the “Delete Buttonon Your Computer当按删除按钮时电脑会讯问他“要删除吗?Factory工厂Dual Palm Buttons and Other Guards on Machinery 设备上运用两个按扭及其他维护安装Bar Coding条码Lock-Out / Tag-Out 锁紧/翻开标签Error Proofing Exercise No. 1防错练习的第一部分Form Teams of Two两个一组List As Many Examples of Error Proofing As You Can, From Everyday L

25、ife从他每天的生活中,列出他能作到的关于防错的许多例子10 Minutes10分钟Application of Error Proofing防错的运用Essential Steps for Error Proofing防错的根本步骤Identify Opportunities for Errors (Critical Factors)识别防错的时机(关键要素)Prioritize Potential Errors for Error Proofing对潜在的错误加以，区分进展防错Absolutely Must Prevent the Defects必需完全的防止错误Provide Conta

26、inment and Study Further预防错误和深化研讨May Be Tolerated, Within Predefined Limits在方案的范围内进展防错Identify Root Causes of the Errors识别错误根源Develop and Evaluate Error Proofing Options 开发和评价防错方案Select and “Design the Error Proofing System选择和设计防错系统Implement - Plan, Install, Document, Train, Monitor实施防错设计反错，安装防错,编制防

27、错文件,培训,监控Periodically Assess the Performance and Improve对防错情况进展定期评审及改良Manufacturing Processes制造过程Product Quality产质量量Process Design过程设计Product Design产品设计What is the Right Time to Error Proof?正确的防错时间是什么时间?100:110:11:1As Early As Possible及早发现Why Error Proof Early During New Product Development为什么在新产品开发

28、期间防错Cost of “Fixing the Defects “修缮缺陷的本钱Concept Development观念开发Preliminary Design初步设计Detailed Product Design详细的产品设计Customer Support客户支持Industrialization产业化Production消费Process Design过程设计Cost of “Fixing 设备的破费Multiplies With Life Cycle Stages整个过程当中的多项防错Stages of Product Life Cycle产品生命周期中各个阶段Why Error P

29、roof Early During Processing在处置期间为什么要尽早防错Cost of “Fixing the Defects设备本钱失效Incoming Parts外协件After Completing the Process过程完成之后At the End of the Line产品最终分开消费线After Delivery to Customer 交付给客户之后Final Test最后检验Cost of “Fixing Increases With Process Steps随着程序步骤增长修复错误本钱增长Steps of Product Processing产品处置的步骤Re

30、ject & Return 废弃件No Delay没有拖延Reject & Scrap废弃件&废品Minor Delay略微拖延Reject & Scrap / Rework废弃件&废品/返工RescheduleSome Delay进度稍有拖延Significant Rework / ScrapAdd to the Production ScheduleDelayed Deliveries重要的返工/废品影响消费进度及产品交付Warranty CostsAdministrative CostsLiabilitiesReputationMarket Share Loss担保本钱及管理本钱添加,导

31、致市场份额损失Error Proofing Exercise No. 2防错训练的第二部分Form Teams of Two两个一组Discuss and Agree on One Example of Product Design or Manufacturing Process to Analyze讨论一个产品设计或制造工艺的例子,并进展分析Identify 鉴别Error Proofing Implemented防错实施Estimate Cost / Quality Impact消除本钱/质量影响OR或者Error Proofing Opportunities Missed丧失防错良机E

32、stimate the Cost / Quality Impact消除本钱/质量影响List Lessons Learned学到的教训清单Prepare to Present to the Class预备到课堂上展现20 Minutes20分钟Identify Opportunities for Errors识别防错的时机Methods for Identifying Potential Errors识别潜在的防错方法Customer Demanded - Good Start消费者的需求-良好的开场Internal Quality Results Reactive内部质量效果-反响Past

33、Experience - Not Completely Reliable以往阅历-不完全可靠Customer 反响 - Too Late消费者的反响-太迟Systematic Analyses to Identify Potential Errors识别潜在的错误需进展系统分析Potential Failure Mode and Effects Analysis (FMEA)潜在的失效方式及效果分析(FMEA)Product FMEA 产品FMEAProcess FMEA过程FMEAPotential Failure Mode and Effects AnalysesPFMEA潜在的失效方式和

34、 效果分析Overview总揽Key Points of FMEAFMEA的关键部分FMEA Analyses Potential FailuresFMEA分析潜在失效Fleas Have to Be Done by Multi-functional TeamsFleas应由多功能组执行Design FMEA Should Be Initiated Before or at the Concept Stage设计FMEA是在开场之前或者概念构成阶段Process FMEA Should Be Initiated Before or at the Feasibility Stage, Prior

35、 to Tooling or Equipment Finalization过程FMEA是在工装及设备调整好开场消费之前或者可研阶段FMEAs Should Be Continuously Updated, As Changes in Product & Process Designs Take Place 应该不断更新,比如FMEAs中的产品&过程设计 FMEAs Are Living Documents FMEAs 是活的文件FMEAs Are Never Ending Processes FMEAs 是永远都不会终了的工艺FMEA Type and LevelsFMEA的类型和程度Desi

36、gn FMEA设计FMEAProcess FMEA过程FMEASubsystem子系统Critical Features关键特性Components / Parts零件Subassemblies分装Workstations任务台Operations加工操作General Information (1)总阐明23456781011912FMEA Steps FMEA 的步骤Design FMEA设计FMEAGeneral Information - Details of the Product & FMEA信息总阐明-产品及FMEA的概略Item Function / Requirement工程

37、的功能/要求Enter All Functions of a Product Item键入一切产品的功能Potential Failure Mode潜在的缺点方式Describe How a Product Item Could Fail描画产品怎样失效Use Physical Terms, Not Symptoms运用公用描画词语,不是病症Process FMEA过程FMEAGeneral Information - Details of the Product & FMEA信息总阐明- -产品的详细资料和FMEAProcess Function 过程功能Enter Description

38、& Purpose of the Process键入过程描画和过程功能Potential Failure Mode 潜在失效方式Describe How Process Could Fail to Meet Requirements of Subsequent Operations描画工艺为什么不能满足分序要求Describe Non-conformance描画不一致性FMEA Steps FMEA的步骤Design FMEA设计FMEAPotential Effect(s) of Failure潜在失效效果Perceived by Customer客户需求Severity (Chart)严肃

39、性图表Seriousness of the Effect of Potential Failure潜在失效效果的严肃性Severity Ranking Reduced Only by Design Change只需设计更改时严肃性级别降低Classification分类Safety / Regulation or Function / Appearance Based平安/规定或功能/根本表象Employ Customers Criteria采用客户规范Process FMEA过程FMEAPotential Effect(s) of Failure潜在失效效果Perceived by Cust

40、omer, Including Subsequent Operations客户需求,包括下述操作Severity (Chart) 严肃性(图表)Seriousness of the Effect of Potential Failure潜在失效效果的严肃性Classification分类Safety / Regulation or Function / Appearance Based平安/规定或功能/根本表象Employ Customers Criteria采用客户规范Severity Rating Chart严肃性级别表格FMEA Steps FMEA步骤Design FMEA 设计FME

41、APotential Cause(s)潜在缘由List All the Causes (Design Weaknesses)列出一切缘由(设计弱点)Occurrence (Chart)频率(图表)Likelihood of the Failure to Occur by the Specific Cause特殊缘由导致失效的能够性Occurrence Ranking Reduced Only by Design Change仅当设计更改时才思索降低发生频率.Design Control设计控制Validation / Verification Activities Which Will Ass

42、ure Adequacy of Design验证/确认活动应确保设计的准确性Process FMEA 过程FMEAPotential Cause(s)潜在缘由Identify Root Cause, and Identify What Can Be Corrected确定缘由,确定可以采取什么纠正措施Occurrence (Chart)频率(图表)Expected Frequency of Failure to Occur by Specific Cause 详细缘由导致失效发生的频率Classification (Chart)类别Process Controls That Prevent o

43、r Detect the Failure预防或探测缺陷的过程控制Occurrence Rating Chart 频率等级表格FMEA Steps FMEA 的步骤Design FMEA设计FMEA Detection (Chart) 检测图表Ability of a Current Design Control to Identify a Potential Cause现行控制设计才干,以识别潜在的缘由当前设计的才干Process FMEA过程FMEA Detection (Chart) 检测图表Assuming Failure Has Occurred, Assess Detection C

44、apability of All the Process Controls假设发生失效,应检测一切工艺控制的才干RPN (Risk Priority No.) RPN(风险优先号)Product of S (Severity), O (Occurrence) & D (Detection)产品的S(严重性),O(发生频率)&D(检测)Used As a Guide to Help Rank Design / Process Concerns为进展设计及过程等级等提供导游No Threshold Value无界限值Pay Special Attention If Severity Is High

45、假设严重级别高的话,应提高警惕Corrective Action, Responsibility, and Monitoring Results实施纠正措施,确定责任人,监控结果1112Detection Rating Chart检测等级表Summarized Rating Chart总结等级表Summary of FMEA Steps FMEA步骤汇总Form a Multi-functional Team组建多功能小组Failure Mode: How Could This Part, System or Process Fail?失效方式:该产品,系统或工艺是怎样失效的?Effect o

46、f the Failure: What Does the Customer Experience As a Result of the Failure?失效影响:作为一种失效方式客户的阅历是怎样的?Cause of Failure: What Conditions Could Bring About the Failure Mode?失效缘由:关于该失效方式会导致什么情况?Occurrence: Probability the Failure Mode Will Occur发生:发生失效方式的能够性Severity: Weighing the Consequence of the Failur

47、e Mode严重性:衡量失效方式的结果Detection: Probability the Failure Mode Will Not Be Detected Before Reaching the Customer 失效:失效方式在到达客户之前不会被检测到.Risk Priority No. (RPN): Product of Occurrence, Severity and Detection, That Provides Relative Priority.风险号(RPN): 产品发生频率,严重性检测,提供了相对优先权.Identify Action Items, Assign Resp

48、onsibility, and Follow Through确定实施措施:分配责任,跟踪执行Essential Steps for Error Proofing 防错的根本步骤Identify Opportunities for Errors (Critical Factors)Prioritize Potential Errors for ProofingAbsolutely Must Prevent the DefectsProvide Containment and Study FurtherMay Be Tolerated, Within Predefined LimitsIdenti

49、fy Root Causes of the ErrorsDevelop and Evaluate Error Proofing Options Select and “Design the Error Proofing SystemImplement - Plan, Install, Document, Train, MonitorPeriodically Assess the Performance and ImproveFMEA Addresses All these Error Proofing Steps FMEA可以定位一切的防错步骤And Helps Planfor These为此

50、设置方案Exercise - 3 Process PFMEA 过程PFMEA练习第三部分Identify One of the Process Steps识别一个过程步骤Walk Through the Steps of PFMEA实施整个PFMEA步骤Fill Out the FMEA Form填写FMEA表格Develop an Action Plan开发实施方案Error Proofing Options防错方案Error Proofing Approaches防错方法Eliminate Potential Defects: Design Out the Potentials for E

51、rrors消除潜在缺陷:对潜在错误进展设计Prevent Defects From Occurring: Identify the Potential of Error, Before It Occurs, and Prevent It防止缺陷发生:识别潜在错误:在错误发生前进展预防Detect the Defect: Error Has Already Occurred, Detect and Remove the Defective Product 检测缺陷:错误曾经发生,检测及移除缺陷件Loss Control: Potential for Defect Exists, Potentia

52、l Exists for Not Detecting, Minimize Damage From the Defect损失控制:存在潜在缺陷,没有对潜在缺陷进展探测,使缺陷的损伤最小化.All These Approaches Overlap, No Clear Boundaries一切方法交错在一同,没有明晰界限Example - Fire Proofing a New Building例如-新 建筑的防火防错Eliminate: Use Only Non-combustible Material for Construction (Steel, Concrete, Etc.)排除：在建筑中

53、要运用不易燃物质钢铁，混凝土等Prevent: Do Not Allow不允许吸烟Electrical System and Components运用正确的电气系统和元件预防：Detect: Install Smoke Detectors and Fire Alarms检测：安装烟雾检测器和火警系统Loss Control: Install Sprinkler System, Fire Extinguishers, Fire Hoses损失控制：安装自动喷淋安装系统，灭火器，灭火水龙带，防火软管等Example - Accident Proof a Railway Crossing例子：测试铁

54、道路口的不测事故Eliminate Accidents: Build a Bridge排除事故：建造一座桥Prevent Accidents: Install an Automatic Gate, In Addition to Lights and Alarms预防不测事故：除了灯和警报安装,安装一个自动门Detect and announce a Passing Train: Install Lights and Alarms检测和进展一个短期培训：安装灯和警报安装培训Loss Control, in Case of an Accident: Install a Pay Phone?损失控制

55、，有不测事故时：安装一个付费?In Many Cases, Loss Control Is NOT an Option在很多情况下,损失控制不是实施方案First Step for Error Proofing Options防错的第一个步骤Decide the Level of Error Proofing Needed需求决议防错的程度Eliminate, If排除，假设Severity Is High严重度高Potential for Occurrence Is Very High发生的能够性很大Detection Is Impossible检测是不能够的Cost of Eliminat

56、ing is Low排除本钱低Prevent, If Design Is Completed, and防止，假设设计完成Severity Is Low严肃性较低RPN Is Low RPM低Attempt Detection in Most Other Cases of Potential for Defects对其他潜在缺陷进展检测Based on Priority以优先权为根底Opportunities for Error Proofing防错的良机消除预防检测损失控制产品设计 工艺/设备设计 车间措施 其他质量保证措施Error Proofing Decision Diagram防错决策

57、图表Potential Error潜在的错误Defect Free Product无缺陷产品Errors Eliminated排除错误Prevent Error from Occurring防止错误发生Eliminate During Product / Process Design在产品/过程设计中消除错误Detect the Defect发现缺陷Defect Detected缺陷检测Defect Prevented缺陷防止Design Loss Control In the Product在产品中设计损失控制Defect Has Serious Consequences缺陷导致严重结果No

58、NoNoNo无Yes有YesYes有YesDevelop Loss Control Procedure开发损失控制程序Key Points for Elimination错误排除的关键点Largest Potential During Design设计中的宏大潜能Eliminate by Designing Out Activities With Potential for Errors对潜在的错误设计活动,进展排除Cost Effective If Addressed Before Finalizing the Designs (Product, Process, Equipment)设计定

59、案之前产品，程序，器材计算本钱成效Most Cost Effective Method of All大多数本钱成效方法Six Sigma Quality Can Be Achieved Only With Extensive Elimination 只需完成大范围消除措施后才可以完成6 SigmaMotorola Mandates All Processes for a New Product to Be Six Sigma Capable摩托罗拉要求一切产品工艺都可以运用6Sigma.Once Eliminated, Nothing Else is Required一旦消除,就不需求其他的了

60、Error Elimination & Symmetry排除错误和对称L1L2L1L1Make Them Asymmetric 使其不均匀分布Make Them Completely Symmetric使其完全均匀分布Partially Symmetric Parts部分平衡件OR或Error Elimination & Dimensioning排除防错和决议错误大小Which is Better?哪一个最好？Ask What is Important and How It Should be Measured什么是重要，应怎样丈量To EliminateModify or Redesign?