精益生产防错概论课件

ErrorProofing

防错ErrorProofing

防错Topics-ErrorProofingTraining

Topics-ErrorProofingTrainiTopics主题ObjectivesoftheTraining培训的目的WhatandWhyofErrorProofing什么是防错，怎样进行防错ApplicationofErrorProofing防错应用IdentifyOpportunitiesforErrors防错时机的确定OverviewofFailureModeandEffectsAnalysis(FMEA)失效模式和效果分析总括ErrorProofingOptions防错的选择Prevention&DetectionThroughPokaYokeDevices通过PokaYoke进行预防与探测MovetoTheNextLevel转入下一级ABenchmarkWithinEaton伊顿内部标准Summary概要Topics主题ObjectivesoftheTraiObjectivesoftheTraining

培训的目的UnderstandWhatIsErrorProofingandWhatItCanDo了解什么是防错和防错能做什么UnderstandthePrinciplesofErrorProofing了解防错的原理LearnHowtoApplyErrorProofingtoProductsandProcesses了解怎样对产品及工艺过程应用防错LearnAboutthePokaYokeDevicesandSystems了解PokaYoke装置和系统LearntheProcessofImplementationandContinuousImprovements了解实施防错的过程和持续改进的过程ObjectivesoftheTraining

培训的WhatAreYourExpectations?

你们的期望是什么？WhatAreYourExpectations?

你们WhatandWhyofErrorProofing

什么是防错以及为什么要防错WhatandWhyofErrorProofingDefinition

定义ErrorProofingIsaSystematicApproachforAnticipatingandDetectingPotentialDefectsandPreventingThemFromReachingtheCustomer(InternalorExternal)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)Definition

定义ErrorProofingIsErrorProofingbyOtherNames

以其他名称进行防错FoolProofing防止愚蠢行为IdiotProofing防止白痴行为MistakeProofing防止错误行为FailSafing安全失效PokaYokeZeroQualityControl(ZeroDefects)零质量控制（零缺陷）DesignforManufactureandAssembly制造和装配的设计LetUsNotArguetheMeritsofTheseNamesLetUsDecideWhatWeWanttoAchieve我们不要争论这些名称,让我们决定想要完成什么?DemoralizingTerms防错术语ErrorProofingbyOtherNames

CharacteristicsofErrorProofing

防错的特点ProactiveIdentificationandPrevention前期识别及预防PreventFirst首先进行防错DoNotAllowDefectFromGoingFurther其次不准许缺陷进一步发展IntentionallyDesigned,NotHappenstance设计错误,非偶然错误.AttheSource-ClosetotheOrigination错误的来源_接近发源地.InexpensiveFirst首先成本不高TransparenttotheOperator操作者很容易发现AbsolutelyReliable错误根源查找绝对准确AMeanstoAchieveZeroDefectProduct一种达到0缺陷产品的方法CharacteristicsofErrorProofDefectsinProductsAretheImperfections(orFaults,orFlaws,orBlemishes,orShortcomings,orFailings,orDeficiencies)

缺陷是指产品里的不完整性(或者故障,或者裂纹,或者瑕疵，或者短处，或者过失，或者不足)ResultingFromErrors错误产生的结果ErrorsAreHumanOversights(orFaults,orBlunders,orBoo-boos,orSlip-ups,orInaccuraciesorMiscalculations)ThatCauseDefectsinProducts错误是人为疏忽(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。DefectsandErrors

缺陷和错误SO,ErrorsCauseDefectiveProducts!!所以,错误导致有缺陷的产品产生!!DefectsinProductsAretheImWhyAreErrorsMade

为什么会导致错误AnyProductIsaResultofNumerousDecisionsMadeandActionsTakenbyHumanBeings,During:任何产品都可以在下述一系列人为行为中产生错误：ProductDesign产品设计ProcessDesign过程设计EquipmentDesign设备设计ComponentFabricationProcesses零件加工过程ProductAssemblyProcesses产品装配过程InspectionProcesses检验过程PaperworkGeneration程序行程过程Etc.等等AndHumanBeingsareFallibleorImperfect人是容易犯错或不完美的WhyAreErrorsMade

为什么会导致错误AnSOMEExamplesofDefects

属于缺陷的一些例子WrongorInappropriateMaterial错误或不适合的材料WrongorNon-functioningComponents错误或者没有功能的零件WrongDimensionsorTolerances尺寸或公差错误MissingComponents零件漏装ForeignMatters,Contamination杂质物质,污秽物DamagedProductorComponents受损产品或零件WrongPaperwork,orWrongProductShipped程序错误或者运输了错误的产品Non-functioningorMalfunctioningProduct没有功能的产品或者是故障产品WrongShipping,orWrongBilling运输错误或者是填单错误SOMEExamplesofDefects

属于缺陷的SOMEExamplesofCausesofDefects

导致缺陷的一些例子PoorDesignDecisions设计比较乏味OmittedorWrongProcessing过程疏忽或过程错误Missing/ExtraPartsorWrongParts漏装/多装了错误的零件OmittedorWrongAdjustment/Testing遗漏调整/测试或调整/测试过程错误WrongEquipmentSetuporLossofSetup设备设置错误或没有进行设备设置WrongMaterial,ComponentsorAssemblies材料，零件或者装配错误WrongCommunication,Instructions,Procedures,orMethods错误的信息，指令，程序，或者方法Inexperience,LackofTraining,WrongTraining,LackofRetraining缺乏经验，缺乏培训，培训错误，缺少再培训SOMEExamplesofCausesofDefSOMEExamplesofResultsofDefects

缺陷导致的结果示例

MalfunctionorNon-functioningProduct有故障或者缺乏机能的产品Inconvenience,Discomfort,Injury,Death麻烦，不便，伤害，死亡Delays,Cancellations延期，取消FinancialLosses财政损失LossofUseorProductivity效用或者生产力的缺乏DamagetoCustomer’sProperty损害客户的利益LiabilitiesandLawSuites负债和法律问题LossofReputationandBusiness名誉和业务受损SOMEExamplesofResultsofDeSOMECausesofHumanErrors

导致人们犯错误的一些原因Forgetfulness,LossofConcentration,LackofAttentionorDivertedAttention健忘，不集中，缺乏注意力或者转移注意力MisunderstandingorLackofUnderstanding误会或者缺乏理解LackoforImproperExperience/Training缺乏经验/培训或者不正确的经验/培训LackofStandardization缺乏标准IntentionalorWillfulError有意图的或者恶意的错误WrongorDelayedDecision决定错误或拖延LimitedorLackofSensoryCapability(e.g.,Smell,Color,Touch)有限的或者没有感官能力（例如，嗅觉，色彩，触觉）LackofApplicationofCommonSense缺乏运用常识判断的能力SOMECausesofHumanErrors

导致ErrorProofinginaFewWords

预防错误的一些方法“…occurrenceofdefectwastheresultofsomeconditionoraction,andthatitwouldbepossibletoeliminatedefectsentirelybypursuingthecause.Thecausesofdefectslieinworkererrors,anddefectsaretheresultsofneglectingthoseerrors.Itfollowsthatmistakeswillnotturnintodefectsifworkererrorsarediscoveredandeliminatedbeforehand.”缺陷的产生是一些环境或者行为导致的结果，但是完全有可能通过查找原因排除缺陷。缺陷原因在于工人，缺陷是因为工人忽视错误而产生的。如果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。ShigeoShingoErrorProofinginaFewWords

WhyErrorProof?

为什么防错？99.9%ErrorFreeCouldResultin99.9%没有错误导致什么结果2,000,000DocumentsLostbyIRSIRS缺少2，000，000档案16,000PiecesofMailLostEveryDay每天丢失16，000邮件22,000WronglyDebited/CreditedChecksPerHour每个小时都会发生22，000写错借方和贷方的支票1,314WronglyConnectedPhoneCallsPerMinute每个小时都会发生1，314起电话占线20,000IncorrectDrugPrescriptionsPerYear每个小时都会发生20，000起用错药物的情况12NewbornBabiesGiventoWrongParents12个小孩被父母抱错2UnsafeLandingsEveryDayatO’HareAirport每天都会有2起飞机不安全着陆32,000MissedHeartbeatsPerPersonEachYear每年每个人都会有32，000Is99.9%GoodEnough???99.9%够不够好???WhyErrorProof?

为什么防错？99.9%ETheErrorsThatBecameHeadlines

错误变成头条TitanicSinking泰坦尼克号的沉没ChallengerBoosterRocketSealFailure挑战者号火箭发射失败MarsLandingModuleCrash火星升空失败坠毁HubbellTelescopeReflectorErrorHubbell望远镜反射误差ExxonValdezOilSpillExxonValdez石油泄露ChernobylNuclearPowerPlantMeltdownChernobylNuclearPower设备报废ReleaseofMethylIsocyanate(MIC)FromUnionCarbidePlantinBhopal,India甲基异丙酮从Bhopal,India,MIC碳化物厂房泄露ThreeMileIslandNuclearPlant三英里小岛的核厂房FirestoneTiresonFordExplorer福特车上的耐火石探测器TheErrorsThatBecameHeadlinErrorProofingandLean防错及精益生产LeanInsistsonOnePieceFlow精益生产强调单件流IfThatOnePieceIsDefective,FlowIsDisrupte如果单件流有缺陷,流向就会被打断LeanInsistsonLimitedInventory精益生产强调有限库存IfThatInventoryIsDefective,theLinesCanSto如果库存有缺陷,线路就会停止LeanMeansEliminatingWaste精益是指消除浪费DefectsandCorrectiveActionsAreWast缺陷以及纠正措施是针对浪费LeanRequiresThatEquipmentIsReadyWhenNeededandFunctionsWellAsLongAsNecessary精益生产要求当需要设备时,设备马上可以用,且功能完好ErrorProofingtheTools,Fixtures,Setups,MethodsandDocumentsEnsuresEquipmentEffectiveness刀具,卡具,启动,方法以及文件等防错以确保设备的有效性ErrorProofingandLean防错及精益生产ErrorProofingExamples

inEverydayLife

在每天生活中防错的一些例子Home家里AutomaticShutoffIrons全自动熨斗GroundFaultCircuitBreakersforBathroomorOutdoorElectricCircuits浴室或室外电气线路的接地保护PilotlessGasRangesandHotWaterHeaters油量表以及热水器Child-ProofCapsonMedicineBottles药瓶上保护小孩安全的瓶盖Retail零售Tamper-ProofPackaging锥型防错包装BarCodingatCheckou检验时的条码Office办公室SpellCheckinWordProcessingSoftware在Wordword处理软件中进行拼写检查Verifying“Doyouwanttodelete?”WhenPressthe“Delete”ButtononYourComputer当按删除按钮时电脑会询问你“要删除吗”?Factory工厂DualPalmButtonsandOtherGuardsonMachinery

设备上使用两个按扭及其他保护装置BarCoding条码Lock-Out/Tag-Out

锁紧/打开标签ErrorProofingExamples

inEvErrorProofingExerciseNo.1

防错练习的第一部分FormTeamsofTwo两个一组ListAsManyExamplesofErrorProofingAsYouCan,FromEverydayLife从你每天的生活中,列出你能作到的关于防错的许多例子10Minutes10分钟ErrorProofingExerciseNo.1

ApplicationofErrorProofing

防错的应用ApplicationofErrorProofing

EssentialStepsforErrorProofing

防错的基本步骤IdentifyOpportunitiesforErrors(CriticalFactors)识别防错的时机(关键因素)PrioritizePotentialErrorsforErrorProofing对潜在的错误加以，区分进行防错AbsolutelyMustPreventtheDefects必须完全的防止错误ProvideContainmentandStudyFurther预防错误和深入研究MayBeTolerated,WithinPredefinedLimits在计划的范围内进行防错IdentifyRootCausesoftheErrors识别错误根源DevelopandEvaluateErrorProofingOptions开发和评估防错方案Selectand“Design”theErrorProofingSystem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,编制防错文件,培训,监控PeriodicallyAssessthePerformanceandImprove对防错情况进行定期评审及改进EssentialStepsforErrorProoManufacturingProcesses制造过程ProductQuality产品质量ProcessDesign过程设计ProductDesign产品设计WhatistheRightTimetoErrorProof??

正确的防错时间是什么时间?100:110:11:1AsEarlyAsPossible及早发现ManufacturingProcessesProductWhyErrorProofEarlyDuring

NewProductDevelopment

为什么在新产品开发期间防错Costof“Fixing”theDefects“修理”缺陷的成本ConceptDevelopment观念开发PreliminaryDesign初步设计DetailedProductDesign详细的产品设计CustomerSupport客户支持Industrialization产业化Production生产ProcessDesign过程设计Costof“Fixing”设备的花费MultipliesWithLifeCycleStages整个过程当中的多项防错StagesofProductLifeCycle产品生命周期中各个阶段WhyErrorProofEarlyDuring

WhyErrorProofEarly

DuringProcessing

在处理期间为什么要尽早防错Costof“Fixing”theDefects设备成本失效IncomingParts外协件AfterCompletingtheProcess过程完成之后AttheEndoftheLine产品最终离开生产线AfterDeliverytoCustomer交付给客户之后FinalTest最后检验Costof“Fixing”IncreasesWithProcessSteps随着程序步骤增长修复错误成本增长StepsofProductProcessing产品处理的步骤Reject&Return废弃件NoDelay没有拖延Reject&Scrap废弃件&废品MinorDelay稍微拖延Reject&Scrap/Rework废弃件&废品/返工RescheduleSomeDelay进度稍有拖延SignificantRework/ScrapAddtotheProductionScheduleDelayedDeliveries重要的返工/废品影响生产进度及产品交付WarrantyCostsAdministrativeCostsLiabilitiesReputationMarketShareLoss担保成本及管理成本增加,导致市场份额损失WhyErrorProofEarly

DuringErrorProofingExerciseNo.2

防错训练的第二部分FormTeamsofTwo两个一组DiscussandAgreeonOneExampleofProductDesignorManufacturingProcesstoAnalyze讨论一个产品设计或制造工艺的例子,并进行分析Identify鉴别ErrorProofingImplemented防错实施EstimateCost/QualityImpact消除成本/质量影响OR或者ErrorProofingOpportunitiesMissed丧失防错良机EstimatetheCost/QualityImpact消除成本/质量影响ListLessonsLearned学到的教训清单PreparetoPresenttotheClass准备到课堂上展示20Minutes20分钟ErrorProofingExerciseNo.2

IdentifyOpportunitiesforErrors

识别防错的时机IdentifyOpportunitiesforErrMethodsforIdentifyingPotentialErrors

识别潜在的防错方法CustomerDemanded-GoodStart消费者的需求-良好的开始InternalQualityResults–Reactive内部质量成效-反应PastExperience-NotCompletelyReliable以往经验-不完全可靠Customer反馈-TooLate消费者的反馈-太迟SystematicAnalysestoIdentifyPotentialErrors识别潜在的错误需进行系统分析PotentialFailureModeandEffectsAnalysis(FMEA)潜在的失效模式及效果分析(FMEA)ProductFMEA产品FMEAProcessFMEA过程FMEAMethodsforIdentifyingPotentPotentialFailureMode

andEffectsAnalyses

PFMEA

潜在的失效模式和

效果分析

Overview总揽PotentialFailureMode

andEfKeyPointsofFMEA

FMEA的关键部分FMEAAnalysesPotentialFailuresFMEA分析潜在失效FleasHavetoBeDonebyMulti-functionalTeamsFleas应由多功能组执行DesignFMEAShouldBeInitiatedBeforeorattheConceptStage设计FMEA是在开始之前或者概念形成阶段ProcessFMEAShouldBeInitiatedBeforeorattheFeasibilityStage,PriortoToolingorEquipmentFinalization过程FMEA是在工装及设备调整好开始生产之前或者可研阶段FMEAsShouldBeContinuouslyUpdated,AsChangesinProduct&ProcessDesignsTakePlace

应该不断更新,比如FMEAs中的产品&过程设计FMEAsAreLivingDocumentsFMEAs是活的文件FMEAsAreNeverEndingProcessesFMEAs是永远都不会结束的工艺KeyPointsofFMEA

FMEA的关键部分FMFMEATypeandLevels

FMEA的类型和水平DesignFMEA设计FMEAProcessFMEA过程FMEASubsystem子系统CriticalFeatures关键特性Components/Parts零件Subassemblies分装Workstations工作台Operations加工操作FMEATypeandLevels

FMEA的类型和水GeneralInformation(1)总说明23456781011912GeneralInformation(1)总说明2345FMEASteps

FMEA

的步骤

DesignFMEA设计FMEAGeneralInformation-DetailsoftheProduct&FMEA信息总说明-产品及FMEA的详情ItemFunction/Requirement项目的功能/要求EnterAllFunctionsofaProductItem键入所有产品的功能PotentialFailureMode潜在的故障模式DescribeHowaProductItemCouldFail描述产品怎样失效UsePhysicalTerms,NotSymptoms使用专用描述词语,不是症状ProcessFMEA过程FMEAGeneralInformation-DetailsoftheProduct&FMEA信息总说明--产品的详细资料和FMEAProcessFunction过程功能EnterDescription&PurposeoftheProcess键入过程描述和过程功能PotentialFailureMode潜在失效模式DescribeHowProcessCouldFailtoMeetRequirementsofSubsequentOperations描述工艺为什么不能满足分序要求DescribeNon-conformance描述不一致性FMEASteps

FMEA的步骤

DesignFMFMEASteps

FMEA的步骤DesignFMEA设计FMEAPotentialEffect(s)ofFailure潜在失效效果PerceivedbyCustomer客户需要Severity(Chart)严肃性（图表）SeriousnessoftheEffectofPotentialFailure潜在失效效果的严肃性SeverityRankingReducedOnlybyDesignChange只有设计更改时严肃性级别降低Classification分类Safety/RegulationorFunction/AppearanceBased安全/规定或功能/基本表象EmployCustomer’sCriteria采用客户标准ProcessFMEA过程FMEAPotentialEffect(s)ofFailure潜在失效效果PerceivedbyCustomer,IncludingSubsequentOperations客户需要,包括下述操作Severity(Chart)

严肃性(图表)SeriousnessoftheEffectofPotentialFailure潜在失效效果的严肃性Classification分类Safety/RegulationorFunction/AppearanceBased安全/规定或功能/基本表象EmployCustomer’sCriteria采用客户标准FMEASteps

FMEA的步骤DesignFMEASeverityRatingChart

严肃性级别表格SeverityRatingChart

严肃性级别表格FMEASteps

FMEA步骤DesignFMEA设计FMEAPotentialCause(s)潜在原因ListAlltheCauses(DesignWeaknesses)列出所有原因(设计弱点)Occurrence(Chart)频率(图表)LikelihoodoftheFailuretoOccurbytheSpecificCause特殊原因导致失效的可能性OccurrenceRankingReducedOnlybyDesignChange仅当设计更改时才考虑降低发生频率.DesignControl设计控制Validation/VerificationActivitiesWhichWillAssureAdequacyofDesign验证/确认活动应确保设计的准确性ProcessFMEA过程FMEAPotentialCause(s)潜在原因IdentifyRootCause,andIdentifyWhatCanBeCorrected确定原因,确定可以采取什么纠正措施Occurrence(Chart)频率(图表)ExpectedFrequencyofFailuretoOccurbySpecificCause具体原因导致失效发生的频率Classification(Chart)类别ProcessControlsThatPreventorDetecttheFailure预防或探测缺陷的过程控制FMEASteps

FMEA步骤DesignFMEAOccurrenceRatingChart频率等级表格

OccurrenceRatingChart频率等级FMEASteps

FMEA的步骤DesignFMEA设计FMEADetection(Chart)

检测（图表）AbilityofaCurrentDesignControltoIdentifyaPotentialCause现行控制设计能力,以识别潜在的原因当前设计的能力ProcessFMEA过程FMEADetection(Chart)检测（图表）AssumingFailureHasOccurred,AssessDetectionCapabilityofAlltheProcessControls假设发生失效,应检测所有工艺控制的能力RPN(RiskPriorityNo.)RPN(风险优先号)ProductofS(Severity),O(Occurrence)&D(Detection)产品的S(严重性),O(发生频率)&D(检测)UsedAsaGuidetoHelpRankDesign/ProcessConcerns为进行设计及过程等级等提供向导NoThresholdValue无界限值PaySpecialAttentionIfSeverityIsHigh如果严重级别高的话,应提高警惕CorrectiveAction,Responsibility,andMonitoringResults实施纠正措施,确定责任人,监控结果1112FMEASteps

FMEA的步骤DesignFMEDetectionRatingChart

检测等级表DetectionRatingChart

检测等级表SummarizedRatingChart

总结等级表SummarizedRatingChart

总结等级表SummaryofFMEASteps

FMEA步骤汇总FormaMulti-functionalTeam组建多功能小组FailureMode:HowCouldThisPart,SystemorProcessFail?失效模式:该产品,系统或工艺是怎么失效的?EffectoftheFailure:WhatDoestheCustomerExperienceAsaResultoftheFailure?失效影响:作为一种失效模式客户的经验是怎样的?CauseofFailure:WhatConditionsCouldBringAbouttheFailureMode?失效原因:关于该失效模式会导致什么情况?Occurrence:ProbabilitytheFailureModeWillOccur发生:发生失效模式的可能性Severity:WeighingtheConsequenceoftheFailureMode严重性:衡量失效模式的结果Detection:ProbabilitytheFailureModeWillNotBeDetectedBeforeReachingtheCustomer失效:失效模式在到达客户之前不会被检测到.RiskPriorityNo.(RPN):ProductofOccurrence,SeverityandDetection,ThatProvidesRelativePriority.风险号(RPN):产品发生频率,严重性检测,提供了相对优先权.IdentifyActionItems,AssignResponsibility,andFollowThrough确定实施措施:分配责任,跟踪执行SummaryofFMEASteps

FMEA步骤汇EssentialStepsforErrorProofing防错的基本步骤IdentifyOpportunitiesforErrors(CriticalFactors)PrioritizePotentialErrorsforProofingAbsolutelyMustPreventtheDefectsProvideContainmentandStudyFurtherMayBeTolerated,WithinPredefinedLimitsIdentifyRootCausesoftheErrorsDevelopandEvaluateErrorProofingOptionsSelectand“Design”theErrorProofingSystemImplement-Plan,Install,Document,Train,MonitorPeriodicallyAssessthePerformanceandImproveFMEAAddressesAlltheseErrorProofingStepsFMEA可以定位所有的防错步骤AndHelpsPlanforThese为此设置计划EssentialStepsforErrorProoExercise-3

ProcessPFMEA

过程PFMEA练习第三部分IdentifyOneoftheProcessSteps识别一个过程步骤WalkThroughtheStepsofPFMEA实施整个PFMEA步骤FillOuttheFMEAForm填写FMEA表格DevelopanActionPlan开发实施计划Exercise-3

ProcessPFMEA

过ErrorProofingOptions防错方案ErrorProofingOptions防错方案ErrorProofingApproaches防错方法EliminatePotentialDefects:DesignOutthePotentialsforErrors消除潜在缺陷:对潜在错误进行设计PreventDefectsFromOccurring:IdentifythePotentialofError,BeforeItOccurs,andPreventIt防止缺陷发生:识别潜在错误:在错误发生前进行预防DetecttheDefect:ErrorHasAlreadyOccurred,DetectandRemovetheDefectiveProduct检测缺陷:错误已经发生,检测及移除缺陷件LossControl:PotentialforDefectExists,PotentialExistsforNotDetecting,MinimizeDamageFromtheDefect损失控制:存在潜在缺陷,没有对潜在缺陷进行探测,使缺陷的伤害最小化.AllTheseApproachesOverlap,NoClearBoundaries所有方法交织在一起,没有清晰界限ErrorProofingApproaches防错方法EExample-FireProofingaNewBuilding

例如-新建筑的防火防错Eliminate:UseOnlyNon-combustibleMaterialforConstruction(Steel,Concrete,Etc.)排除：在建筑中要使用不易燃物质（钢铁，混凝土等）Prevent:DoNotAllow不允许吸烟ElectricalSystemandComponents使用正确的电气系统和元件预防：Detect:InstallSmokeDetectorsandFireAlarms检测：安装烟雾检测器和火警系统LossControl:InstallSprinklerSystem,FireExtinguishers,FireHoses损失控制：安装自动喷淋装置系统，灭火器，灭火水龙带，防火软管等Example-FireProofingaNewExample-AccidentProofa

RailwayCrossing

例子：测试铁道路口的意外事故EliminateAccidents:BuildaBridge排除事故：建造一座桥PreventAccidents:InstallanAutomaticGate,InAdditiontoLightsandAlarms预防意外事故：除了灯和警报装置,安装一个自动门DetectandannounceaPassingTrain:InstallLightsandAlarms检测和进行一个短期培训：安装灯和警报装置培训LossControl,inCaseofanAccident:InstallaPayPhone??损失控制，有意外事故时：安装一个付费电话??InManyCases,LossControlIsNOTanOption在很多情况下,损失控制不是实施方案Example-AccidentProofa

RaFirstStepforErrorProofingOptions

防错的第一个步骤DecidetheLevelofErrorProofingNeeded需要决定防错的水平Eliminate,If排除，如果SeverityIsHigh严重度高PotentialforOccurrenceIsVeryHigh发生的可能性很大DetectionIsImpossible检测是不可能的CostofEliminatingisLow排除成本低Prevent,IfDesignIsCompleted,and防止，如果设计完成SeverityIsLow严肃性较低RPNIsLowRPM低AttemptDetectioninMostOtherCasesofPotentialforDefects对其他潜在缺陷进行检测BasedonPriority以优先权为基础FirstStepforErrorProofingOpportunitiesforErrorProofing

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OpportunitiesforErrorProofiErrorProofingDecisionDiagram

防错决策图表PotentialError潜在的错误DefectFreeProduct无缺陷产品ErrorsEliminated排除错误PreventErrorfromOccurring防止错误发生EliminateDuringProduct/ProcessDesign在产品/过程设计中消除错误DetecttheDefect发现缺陷DefectDetected缺陷检测DefectPrevented缺陷防止DesignLossControlIntheProduct在产品中设计损失控制DefectHasSeriousConsequences缺陷导致严重结果NoNoNoNo无Yes有YesYes有YesDevelopLossControlProcedure开发损失控制程序ErrorProofingDecisionDiagraKeyPointsforElimination

错误排除的关键点LargestPotentialDuringDesign设计中的巨大潜能EliminatebyDesigningOutActivitiesWithPotentialforErrors对潜在的错误设计活动,进行排除CostEffectiveIfAddressedBeforeFinalizingtheDesigns(Product,Process,Equipment)设计定案之前（产品，程序，器材）计算成本效用MostCostEffectiveMethodofAll大多数成本效用方法SixSigmaQualityCanBeAchievedOnlyWithExtensiveElimination只有完成大范围消除措施后才可以完成6SigmaMotorolaMandatesAllProcessesforaNewProducttoBeSixSigmaCapable摩托罗拉要求所有产品工艺都可以使用6Sigma.OnceEliminated,NothingElseisRequired一旦消除,就不需要其他的了KeyPointsforElimination

错误排ErrorElimination&Symmetry

排除错误和对称L1L2L1L1MakeThemAsymmetric使其不均匀分布MakeThemCompletelySymmetric使其完全均匀分布PartiallySymmetricParts部分均衡件OR或ErrorElimination&Symmetry

排ErrorElimination&Dimensioning

排除防错和决定错误大小WhichisBetter?哪一个最好？AskWhatisImportantandHowItShouldbeMeasured什么是重要，应怎样测量ErrorElimination&DimensioniToEliminate

ModifyorRedesign?

通过修改或重新设计排除错误?SomeDefectscanbeRemovedbyModifications许多缺陷都可以通过修改排除OthersMayNeedRedesign其他许多需要重新设计ToEliminate

ModifyorRedesigKeyPointsforPrevention

预防的关键点EliminationIsBestWaytoPrevent排除是最好的预防方法RobustDesign精力充沛的设计DesigntoTolerateUnavoidableVariations对不可避免的变化进行设计EnsuresAcceptableProductsforWiderVariations

确保可以接受的产品允许有较大的变化DesignSoThatErrorsCannotBeMade设计,以免会产生错误DesignProducts,Processes,Equipment,FixturesThatWillPreventWrongPartsFromBeingUsed(PokaYokeDevices)设计(PokaYoke装置)产品,工艺,设备,卡具等可以防止错误的装置.Procedures,Training,DocumentationThatHelpPreventErrors防止错误的程序,培训文件等ErrorProofDocumentGeneratingProcesses-ThatWillPreventManyDefectsFromReachingtheCustomer防止错误的文件-阻止太多缺陷到达客户.Drawings,etc.图纸等ReturnUnacceptableProductBacktothe“Supplier”把不合格件返回供应商.InstitutionalizePreventionMindset结构化预防措施KeyPointsforPrevention

预防的关ConceptsforPrevention

ontheShopFloor车间预防的理念AlwaysProvideAidforCounting为计算提供依据HelpIndicateSelectionofParts帮助进行零件选择ColorCoding,LightedIndicators彩色码,彩灯指示器ProvideOnlyWhatIsNeeded,PreventAccesstoOthers仅提供所需要的,阻止进入其他部分VerifyMachineSettingsThatControlCriticalDimensionsBeforeMachining验证设备装置等,可以在加工前控制标准尺寸EmployTPMforEquipmentandDies设备及模具可以实施TPMImplementMechanismsThatHelptheOperators实施操作者易使用的机械装置BarCoding,CheckLists,GraphicWorkInstructions条码,检验列表,图表化的操作说明InvolvetheOperators包括操作者CarefullyDispositionRejectedParts仔细处理不合格件AvoidRepetitive,Monotonous,HazardousTasks避免重复，单调，危险的任务Standardize标准化ConceptsforPrevention

onthDesignedtoPreventDefects

预防缺点的设计DesignedtoPreventDefects

预防SensorstoDifferentiateIdenticalParts

区别可互换零件的传感器L1L2AlmostIdenticalParts几乎是可互换零件CoordinatedLightSensorsDifferentiatetoPreventErrors用灯传感器来区分预防错误SensorstoDifferentiateIdentDetectPresenceorAbsencetoPreventDefects

使用存在或不存在缺陷的方法预防缺陷Verify

PresenceofScrewstoPreventAssembliesWithoutScrews确定螺丝的存在来预防装配忘记螺丝DetectSplicetoHelpDiscardtheSection探测接口帮助废弃某部分Verify

LiquidLeveltoPreventShippingUnfilledBottle确认液体水平,来预防未装满瓶子运走DetectPresenceorAbsencetoVariousTypesofCounters

toPreventDefects

各种型号的计算器来防止缺陷2134BreakingtheLightCurtain断掉灯的线路LightReflectingSensors灯光反映感应器InductanceSensors自感应器VariousTypesofCounters

toKeyPointsforDetection探测的关键点PokaYokeDevicesCanAddressMostoftheManufacturingDefectsPokaYoke装置可以探测大多数生产缺陷的位置DetectionTakesCareofWhatWasNotPreventedUpstream,orintheCurrentProcess可以探测到以前没有预防住的点,或现场工艺中的错误DetectionShouldTarget“Direct”Parameter,Examples:探测需定位正确的参数,例如:MeasurePressureUndertheNut,NottheTorque测量螺母下面的压力,而不是扭矩下面的压力MeasureWeldStrength,NotWeldingCurrent测量焊接件的强度,而不是焊接件的电流DetectionMustBeClosetotheProcess探测必须接近工艺RightBeforeforIncomingParts进件以前正确RightAfterforCompletedActivity完成活动以后正确DetectionShouldRejectUnacceptableParts&ProvideImmediatefeedback(PokaYokeDevices)探测应拒收不合格件&立即提供反馈(PokaYoke装置)DetectionShouldBeReliable,CertifiableandMonitored探测须是可靠的,有保证的,可以监控的.KeyPointsforDetection探测的关键点MeasureDimensions(Go,NoGo)

toDetectDefects

测量尺寸(通止规)来探测缺陷MeasureSheetThickness测量钢板厚度MeasureDiameter测量直径MeasureSheetWidth测量钢板宽度MeasureDimensions(Go,NoGo)DetectDifferentFeatures

探测不同的特性DetectPickupofaSheet探测钢板位置DetectPresenceofFeatures探测特性的存在性DetectColorAccuracy探测颜色精确性DetectDifferentFeatures

探测不同DetectionUsingContact

使用接触探测RememberThisPart?是否记得这个零件?WhattoDoIfItCannotberedesigned?如果不能重新设计怎么做FixtureDesignedtoDetectIncorrectOrientation设计卡具检测位置正确性DetectionUsingContact

使用接触探测DetectingDimensionUsingContact用接触法测定尺寸Accept可接受件Reject废弃件GoodPart合格件BadPart不合格件DetectingDimensionUsingContKeyPointsforLossControl损失控制的关键点Design,IntheProduct,AvoidanceofCatastrophicResults在产品设计中避免大的损失SeveralBackupSystemsinAircraft,EjectionSeats,Parachute航行器,排除座,降落伞的备份系统Airbag安全气袋LimitedClinicalTrialsonHumansofNewDrugs新药物对人进行临床实验FinalFunctionalTests,BeforeShipping运输前的最后功能实验NothingDetectedonIndividualParts不对单独件进行检验ScheduledMaintenanceChecksofMissionCriticalItems对于关键项目任务提供定期维修ShouldBetheLastResort对关键物品进行定期维修检验,应该有检验报告DriversDoGetinAccidents,SaveThemWithAirbags司机遇到交通事故时,安全气囊可以对他们进行保护NOTDesignUnsafeCars不要设计不安全的汽车EarlyCommunication,RecallsAreExtremelyImportantforLossControl早期交流,招回对损失控制是非常重要的KeyPointsforLossControl损失控TraditionalQualityControl

VersusErrorProofing

传统的质量控制与防错进行比较Op1Op2Op3Op4Test/Inspect检验/检测Scrap废品Accept接受Op1Op2Op3Op4Verify确定确认Verify确定确认Verify确定确认Feedback反馈Feedback反馈Feedback反馈Traditional,CompleteProduct&TestorInspect传统,完成产品实验及检验ErrorProofing,Verify

AfterEveryOperation&反馈每一序后以及反馈后进行防错确认DetectionVersusPrevention探测与预防的比较TraditionalQualityControl

VTraditionalQualityControl

VersusErrorProofing

传统的质量控制与防错进行比较TraditionalQUALITYCONTROL传统质量控制InspectorTestFunctionalitytoDetectDefectiveproduct(FinalProductDefect)功能检测及实验来探测缺陷产品(最后产品缺陷)TheTestProduces“Accept”“Reject”Judgement通过实验选出合格件与不合格件TestorInspectAfterSeveralOperations几序以后进行实验与检测DifficulttoPinpointCauseoftheDefect精确找出缺陷原因很困难NoDirectfeedback

totheOffendingOperation对于不稳定序没有直接反馈LongDelayBetweenError&DiscoveryofDefect错误产生与发现缺陷之间拖延太长ErrorProofing防错Verify

SpecificCharacteri-stic&PreventErrororDetectInter-processDefect确定具体的防错以及工艺缺陷预防Verification“Catches”DefectiveComponent确认捕捉缺陷件VerificationIsImmediate立即确认RelationofDefect&ErrorIsAlreadyKnown缺陷与错误之间的关系已知道FeedbackIsImmediate立即反馈NoDelayinDefectDiscovery不能拖延缺陷件的发现TraditionalQualityControl

VTraditionalQualityControl

VersusErrorProofing-Results

传统的质量控制与防错进行比较-结果Op1Op2Op3Op4Test/In