研发项目管理培训材料差错预防

MistakeProofing差错预防杨振宇（MikeYoung）LMRoadMap精益管理实践路标

全面生产维护TPM统计过程控制

精益系统导入

现场改善

流线化设计

直观化管理

看板管理

快速换模SMED

标准化作业均衡生产5S与质量意识时间与动作分析精益物流价值流图析VSM差错预防精益成熟度评估生产准备流程精益促进者培训问题防止StrategicQuestions战略问题Doesyourorganizationseetheachievementofzerodefectsasarealisticgoal?

你的组织是否看到把零缺陷作为实际的目标所产生的巨大成就？Doesyourorganizationvaluezerodefectsasnecessarytolong-termsuccess?

你的组织是否把零缺陷看作是长期成功的必然要素？SectionOne:第一部分

WhyUseMistakeProofing?为什么要使用差错预防Definition：mistakeproofing差错预防的定义What‘sholdingyouback?是什么在阻碍你们？Value-addingandnonvalue-adding增值与非增值作业分析Aparadigmshift一种观念的突破Benefitsofmistakeproofing差错预防的好处Definition:定义MistakeProofing:差错预防Aprocessimprovementsystemthatpreventsfaultyproductsandavoidsthecostsrelatedtothedispositionandtrackingofdefects.

一个防止产生有缺陷的产品并避免相关处理以及追溯缺陷所造成的代价的过程改善系统What'sHoldingYouBack?

是什么阻碍了您？Whatpreventsyoufromachievingperfectquality?A.K.A.“ZeroDefects”

什么阻碍你获得“零缺陷”的完美品质？Issues放行Practices习惯Attitudes态度Policies政策Otherobstacles其他障碍FiveElements五个要素质量问题常常藏身在上述五个因素中，改善需要对其根源原因进行分析Operator人Materials物料Machines设备Information信息Method方法FourMajorFactorsinProduction

Flow生产流程中的四个主要因素Transformation转换Inspect/Rework检验/返工Transport搬运Store存储Lookingatthesefactors,wecancreateadefinitionofwaste.这些因素中包含着浪费ProcessandOperation流程与运作ABCNInspect-Non-Value-AddingOperation检验—非增值作业Transform-Value-AddingOperation变形—增值作业Transformation变形Inspect/Rework检验/返工Transport运输Store储存PROCESS增值-VA非增值-NVADefinition定义Non-Value-AddingProcess:非增值过程Thoseprocessstepsthattaketime,resources,orspace,butdonotaddvaluetotheproductorserviceitself.虽然占用了资源、空间及节拍时间，但对产品或服务本身而言不增加价值Value-AddingProcess:增值过程Anactivitythattransformsorshapesrawmaterialsordatatomeetcustomers’requirements.为满足顾客需求而使原材料发生形变或数据转换活动ProcessTime流程时间95%oftheactivitiesrelatedtoagivenprocessdonotaddvaluetotheproduct.95%的管理活动是不增值的。NVA5%VATotalManufacturingLeadTime全部生产交付时间95%InspectiontoDiscoverDefects

为了发现缺陷而检验Productsarecomparedwithstandardsanddefectiveitemsareremoved

和标准进行对比，有缺陷的被拿走Samplinginspectionisusedwhen100%inspectionistoomuchtrouble

全检太麻烦的时候采用抽样检验Assumptions假设Defectsareinevitable缺陷不可避免Morerigorousinspectioncan"reduce"defects

更多严格的检验能“减少”缺陷InspectiontoReduceFutureDefects

为了减少未来的缺陷而检验Statisticalqualitycontrolactivities"inspect"processestoanticipateandavoiddefects.

统计质量控制扮演“检验”的角色，用以预期和避免缺陷。Basedonstatisticalanalysis,teamseliminatespecialcauses(processcontrol)andreducevariation(processcapability).

基于统计分析的结论，团队消除特殊原因（过程控制）以及减少变异（过程能力）。Assumptions假设Somelevelofdefectsisinevitableandacceptable.

一些等级的缺陷是不可避免并且是可接受的。Focusisonresultsratherthancauses.

聚焦在结果而不是原因。Inspection检验Althoughitisnecessarytohaveefficientinspectionoperations,theyareoflittlevalueintheprocess.Eventhemostefficientinspectionoperationsaremerelyefficientformsofwaste.

尽管有效的检验是必须的，但它们对流程仅有很小的价值，甚至大部分的检验只是一种有效率的浪费形式。Inspectionplaysapassiveroleinproduction-byitselfitcannotreducedefects.检验不可能减少缺陷Benchmarking你能接受这样的标杆吗？Whatdoes99%OKora3.8Sigmalevelmean?200,000Wrongdrugprescriptionseachyear

每年开错200000个药物处方20,000Lostarticlesofmailperhour

每小时弄丢20000个邮包5,000Incorrectsurgicaloperationsperweek

每周5000个手术做错2Crashlandingsatmostmajorairportseachday

每天在大部分重要的机场有2架飞机坠毁Howabout99.9997%ora6Sigmalevel?68Wrongdrugprescriptionseachyear每年开错68个药物处方7Lostarticlesofmailperhour每小时弄丢7个邮包1.7Incorrectsurgicaloperationsperweek每周1.7个手术做错1Crashlandingevery5years

每5年有1架飞机坠毁ParadigmShift

观念突破Toreducedefectswithinproduction,wemustrecognizethatdefectsaregeneratedbytheworkandallinspectionscandoisdiscoverthosedefects.为了减少缺陷，我们必须认识到缺陷是作业产生的，而所有的检验能做的仅仅是发现它们BenefitsofMistakeProofing

差错预防的好处Enforcesoperationalproceduresorsequences.

确保运作程序的执行Preventsproductdamage.

防止产品缺陷Signalsorstopsaprocessifanerrorismadeoradefectiscreated.

当一个错误发生或缺陷产生时停止一个过程，或发出警告信号Eliminateschoicesleadingtoincorrectactions.

消除导致不正确操作的选择Preventsmachinedamage.

防止设备损坏...AndinConclusion小结Mistakeproofingisaprocessimprovementsystemthat:差错预防是一个过程改善系统Preventsfaultyproducts

防止有差错的产品Preventsmachinedamage

防止设备损坏Mistakeproofinghelpsusachievezerowasteandzerodefects.

差错预防帮助我们实现“零浪费”和“零缺陷”SectionTwo:第二部分TrackingDefectsToTheirSource追踪缺陷到源头Trackingdefects追踪缺陷

Threetypesofinspection检验的三种类型Mistakeproofingandzerodefects差错预防和零缺陷Zerodefectssystem

零缺陷系统Five-levelratingsystem五级评估系统TrackingDefects

缺陷追踪Typicallywetrackdefectsby

通常我们用以下参数追踪缺陷：Quantity数量Kind种类Percent百分比Witha"zerodefects"focuswemusttrack如果是零缺陷我们则必须追踪：Thepointatwhichthedefectisdiscovered

缺陷被发现的位置Thepointatwhichthedefectoccurs缺陷发生的位置ThreeTypesofInspection

检验的三种类型SelfChecks

自检SuccessiveChecks

互检SourceInspection

源头检验Definition:定义

SelfCheck:自检Theoperatorperformingworkchecksitbeforepassingitontothenextprocess.Thisisself-inspectionbytheoperatorthroughsensoryandvisualcues.

操作者在向下道工序移交工作前进行的工作检查，一般靠感觉和视觉提示。Definition:SuccessiveCheck:互检Theoperatorcheckstheoperationsthatwereperformedbythepreviousoperatorpriortoaddinganyvalueattheirstation.

操作者在工作开始前对前面操作者输出的检查。Definition:SourceInspection:源头检验Takingpreventiveaction,attheerrorstage,topreventerrorsfromturningintodefects--ratherthantakingcorrectiveactionafterdefectshaveoccurred.

在错误发生阶段进行预防性检查，防止错误变成缺陷，而不是在缺陷发生后才进行纠正措施。SourceInspection源头检验Cause原因Error错误Action行动Check&Feedback检查与反馈Effect结果Defect缺陷Check&Feedback检查与反馈Action行动DefectDetectionCycle缺陷检测环DefectPreventionCycle缺陷预防环MistakeProofingSystem差错预防系统100%Inspection全检PromptFeedback&Action迅速反馈与行动ZeroDefectsSystem零缺陷系统100%Inspection全检PromptFeedback&Action迅速反馈与行动ZeroDefects!零缺陷Error错误Action行动Check&Feedback检查与反馈DefectPreventionCycle缺陷预防环Cause原因SourceInspection源头检验MistakeProofingSystem差错预防系统+=FoundationforZeroDefects

零缺陷的“地基”Physicalcheckingfunctionsincorporatedintotheoperation检查功能与运作融为一体ZeroDefects零缺陷Promptfeedbackandcorrectiveactionwherethedefectisgenerated.缺陷发生时迅速的反馈与纠正100percentvalidationofeachproductioncycle每个生产循环100%进行确认5LevelsofQualityAssuranceAchievement

五级质量保证水准评估Level水平Effect结果Inspection检验ZDAction零缺陷行动1Plantshipsdefectiveproducts工厂交付有缺陷的产品Lotsofdefectsandlotsofcustomercomplaints大量的缺陷与顾客抱怨None没有Shutdownthefactory关闭工厂2Plantdoesnotshipdefectiveproducts工厂不交付有缺陷的产品Lotsofdefectsbutnocustomercomplaints大量的缺陷但没有顾客抱怨Judgmentinspection判断型检验Usemoreinspectors使用更多的检验员3Plantisreducingdefects工厂正在减少缺陷Defectsproducedinoneproductionrunarenotrepeatedinnextproductionruns同样的缺陷不会重复发生Informativefeedbackinspection;SPC信息反馈型检验统计过程控制Boostkaizenimprovements推进改善4Plantprocessesdonotsenddefectsdownstream工厂设立不发送缺陷给下游工序的流程Whendefectsareproduced,theydonotgetpassedontothenextprocess缺陷不会流到下游工序successiveandself-checks自检与互检Trainoperatorstoidentifyandremovedefects对操作者识别和处理缺陷进行培训5Plantprocessesdonotcreatedefects工厂设立不产生缺陷的流程Whenanerroroccurs,theprocessdoesnotproducedefects错误不会产生缺陷Inspectionatthesource源头检验ZeroDefects,ZeroWaste,ZeroDelays零缺陷、零浪费、零延迟WhereDoYouStand?

看看你在哪个水平？水平:结果:检验:ZD行动:…AndinConclusion小结Toachievezerodefects,weneedbothsourceinspectionandmistakeproofing.

为了获得零缺陷，我们需要源头检验和差错预防SectionThree:第三部分ErrorsandDefects错误与缺陷AnalysisofQualityProblems.

品质问题分析Thedifferencebetweendefectsanderrors.

缺陷与错误的差异Sampledefectsanderrors.

缺陷与错误的例子AnalysisofQualityProblems

品质问题分析Part#部件Defect缺陷Scrap/Rwk废品/返工Found发现Made形成Time-Distance时间—距离Whatistheproduct?什么产品？Whatisthedefect?什么缺陷？Didthedefectresultinscraporrework?缺陷导致废品还是返工？Wherewasthedefectfound?在哪发现缺陷？Wherewasthedefectmade?缺陷在哪形成？Thenumberofoperationsorhours?操作的数量或时间多少？DefectsandErrorsAreNOTtheSame

缺陷与错误不是一回事Defectsareresults.Errorscauseresults缺陷是结果，错误导致结果

Cause原因 Result结果 Errors错误 Defects缺陷EverydayExamplesofErrorsandDefects

错误和缺陷日常小例子Notsettingthetimeronyourtoasterproperly烤面包器的时间设置不恰当Placingthe"original"inyourcopierfaceup在你的复印机面朝上放上“原稿”Runningoutofinkonyourdatecoder你的日期喷码器没有墨了Why?Burnttoast面包烤糊了Manyblankpages许多空白纸Nodatecodeontheproduct产品上没有日期码Defectsvs.Errors缺陷与错误Definition定义Error:错误Whenanyoftheconditionsnecessaryforsuccessfulprocessingarewrongorabsent.完善的处理/加工过程所必须的各种条件发生错误或缺失Processingomissions

加工遗漏Processingerrors

加工错误Errorinsettinguptheworkpiece

工件设置错误Assemblyomissions(MissingParts)

装配漏件InclusionofImproperpart/item

混件

Wrongworkpiece

工件搞错了Operationserrors

操作失误Adjustment,measurement,dimensionalerrors

调整/测量尺寸失误Errorsinequipmentmaintenanceorrepair

设备维护或修理错误Errorinpreparationofblades,jigsortools

准备刀夹具或工具失误TenMostCommonErrors

10个常见错误DamagedParts/Product

部件或产品损坏ReversedParts/Product部件或产品返工ForeignMatterPresent

夹杂MismatchedParts

部件不匹配MisalignedParts

错开的部件

Cannotbeassembled

不能装配Inconsistenttestresults/testfailure

不一致的测试结果/测试失败Badingmaterial

糟糕的来料Wrongmaterial/parts

错误的物料/部件Wrongorinconsistentdimensions

错误或不一致的尺寸Other...?

其他…..CommonDefectCategories

常见缺陷目录...AndInConclusion小结Inanalyzingproblems,youmustunderstandthaterrorsanddefectsarenotthesame.

在分析问题的时候，你一定要知道错误和缺陷不是一回事。SectionFour:第四部分RedFlagConditions红旗条件Inevitabilityofhumanerror

错误不可避免Whatareredflagconditions?

什么是红旗条件？Exercise:identifyredflagconditions

课堂练习：识别红旗条件HumanError-TwoImportantPremises

关于错误的两个前提Errorsareinevitable错误不可避免Errorscanbeeliminatedthroughourcreativeefforts

通过我们的努力错误可以被消除RedFlagConditions

红旗条件Aconditioninthemanufacturingprocessthatcommonlyprovokeserrors制造流程中通常容易出错的情景条件RedFlagConditionsAdjustments（调整/校正）Tooling/toolingchanges（使用工具/加工切换）Dimensions/specifications/criticalconditions（尺寸/规格/关键条件）Manyparts/mixedparts（零部件混装）Multiplesteps（步骤太多）Infrequentproduction（少量生产）Lackofaneffectivestandard（缺少有效的标准）Symmetry（对称）Asymmetry（不对称）RapidRepetition（快速复制）High/extremelyhighvolume（过大的数量/体积）Environmentalconditions（环境条件）Materials/processhandling（材料/工艺操作）Foreignmatter（外部因素）Poorlighting（差的照明）Housekeeping（勤务）RedFlag1Adjustments调整1位置不正RedFlag2Tooling/toolingchanges使用工具/加工切换2参考基准上边缘被用于定位参考基准每个孔都是正确的深度吗？RedFlag3Dimensions/Specifications/CriticalConditions尺寸/规格/关键条件3RedFlag4ManyParts/MixedParts零部件太多或混装4你不曾遗忘过什么吗？RedFlag5MultipleSteps步骤太多5我在哪一步？RedFlag6InfrequentProduction非常规产品6RedFlag7Lackofaneffectivestandard缺少有效标准7这个容器里应放多少物料？RedFlag8Symmetry对称性8RedFlag9Asymmetry非对称性9RedFlag10RapidRepetition快速复制10RedFlag11HighVolume/ExtremelyHighVolume大容量/极大容量11RedFlag12EnvironmentalConditions环境条件12tTeamExercise（团队练习）Trytoidentifytheredflagconditionsinthefollowingexamples:

在下述示例中尝试识别红旗条件Example1（示例1）纽扣应该均匀等距的缝制纽扣握持器视线看的角度纽扣Example2（示例2）流程还是仪表有错误？Example3（示例3）在检查的时无法看到已装好的隐蔽部件Example4（示例4）A-D杠杆按钮Example5（示例5）封闭的箱子–空的还是满的？Example6（示例6）可能反向安装装配口电路板屏蔽箱对称的安装插片Example7（示例7）有刻痕无刻痕一体的部件...AndInConclusion（小结）Redflagconditionsarethosewhichcommonlyprovokeerrors.

红旗条件指的是通常容易出错的作业方法或条件.SectionFive:第五部分DevelopMistakeProofingDevices开发防错装置Definition:Areliablemethod定义：一种可靠的方法Theimprovementcycle

改善环Howtodevelopmistakeproofingdevices

如何开发防错装置ThecyclebeginswithadherencetothecurrentproceduresTheImprovementCycle改善环Standardization标准化Analysis分析Improvement改善Westandardizethesuccessfulimprovementsandcontinuethecycle将成功的改善方案加以标准化，并持续该循环Weanalyzewhatwearedoingandtheresultswearegetting分析正在进行的操作以及由此而产生的结果Baseduponouranalysis,wetakeimprovementaction基于分析结果，采取改善措施AdherenceDefinition:定义ReliableMethod可靠性方法Ismadeupofonlythoseelementswhich,whenfollowed,causeapredictableanddesirableresult,andwhennotfollowed,resultinapredictabledefectorwaste.该方法应由一系列要素构成，当遵循这些要素时，将产生预期的可预测的结果，反之，将导致可预知的缺陷或浪费。SevenStepstoMistakeProofing

差错预防七步骤Step1:步骤1

Identifyanddescribethedefect识别并描述缺陷Step2:步骤2

Determinewherethedefectisdiscoveredormade明确缺陷发生或发现之处Step3:步骤3 Detailthecurrentstandardprocedure详细描述当前的标准程序Step4:步骤4 Identifydeviationsfromstandards识别现有标准的变异Step5:步骤5 Identifytheredflagcondition(s)wherethedefectoccurs在缺陷发生之处，识别红旗条件Step6步骤6 Identifythetypeofmistakeproofingdevicerequiredtopreventtheerrorordefect设计差错预防装置以防止错误或缺陷发生Step7:步骤7 Createdevice(s)andtestforeffectiveness对装置有效性进行测试MistakeProofing

DevelopmentChart差错预防装置开发表Operation:_______________Product:___________________Date:_______________1A.DescribetheDefect:1B.ShowtheDefectRate:2.Identifythelocationatwhichthedefectis..Discovered:_________________________Made:_____________________________TimeDefects3.Detailthecurrentstandardprocedures/elementsoftheoperationwherethedefectismade(onestandard/elementpercard).4.Errorsordeviationsfromstandardswheredefectismade:5.Analyzethecauseforeacherror/deviation:Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?RedFlagConditionsKeepAskingWhy?SourceErrorsIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdea6.Ideastoeliminateordetecttheerror.CheckMistakeProofingDeviceRequiredLevel1:EliminatecauseoferroratthesourceLevel2:DetecterrorasitismadeLevel3:Detectdefectbeforeitreachesnextoperation7.CreateMistakeProofingDeviceCurrentConditionMistakeProofingDeviceCurrentConditionMistakeProofingDeviceCosttoInstall:Remarks:TimetoInstall:Date:CosttoInstall:Remarks:TimetoInstall:Date:MistakeProofingImprovementStep1:Defect缺陷Step2:Location定位Step3:Operations操作Step4:Errors/Deviations

错误/变异Step5:Analysis分析(5–Whys)Step6:ImprovementIdeas改进建议Step7:ImplementedDevices完成装置5Whys–Methodology“5个为什么”方法论Question“Why”agivensituationexistsorconditionhasoccurred.就现有状态或问题发生条件询问“为什么”Documenttheresponse.将答案记录下来Evaluatetheresponse:“Why”didthishappenor“Why”isittrue.评估答案：为什么会发生/为什么它是正确的Documenttheresponse.将答案记录下来Repeattheprocessuntiltherootcausefororiginalproblemisdetermined.重复该过程，知道最终确定问题发生的根源Step5步骤5

Analysis分析-

(WhyProblemIsOccurring)寻找问题发生的根源WHY?为什么5Whys–Example“5个为什么”示例Whydidthemachinestop?机器为什么停机？Becausethefuseblewduetoanoverload因为负载过大保险丝烧断Whywasthereanoverload?为什么会出现负载过大？Becausethebearinglubricationwasinadequate.因为润滑不充分Whywasthebearinglubricationinadequate?为什么润滑不充分？Becausethelubricationpumpwasn’tworking.因为润滑装置失效Whywasn’tthepumpworking?为什么该装置失效？Becausethepumpaxlewaswornout.因为装置轴承出现磨损Whywasitwornout?为什么出现磨损？Becausesludgegotonit.因为碎屑附着在上面Step5步骤5

Analysis分析-

(WhyProblemIsOccurring)寻找问题发生的根源AnalyzethefollowingproblemandconstructaFiveWhysDiagram:分析下列问题并制作“5个为什么”表Youjustfinishedaprojectandwantedtomake5copiesof20pages,collatedandstapled.Yougotothecopierandputtheoriginalinthetrayontop.Yousetthecopierfor20copies,collatedandstapledandhitthe“on”button.Nocopiesaremade.Themachineisoutofpaper.你刚刚完成一个项目报告20页，希望复制5份并校对装订。你走向打印机并将初始文稿放在打印口，将机器设置为复印20份并校对装订，同时按下了开始按钮。文稿没有被复印。机器没纸了。Yourcauses(theanswerstothefivewhys)maybealittledifferentfromtheanswersheet,butyouwillrecognizethecauses.您的答案可能与答题纸显示稍有不同，不管怎样，您终究能找到根本原因。5WhyExercise“5个为什么”练习5WhyTargetForm“5个为什么”目标表为什么Why?Problem:问题Cause:原因Cause:原因Cause:原因Cause:原因RootCause:根本原因为什么Why?为什么Why?为什么Why?为什么Why?UsingCardsontheMistake

ProofingChart在差错预防表格中使用卡片StandardElementsoftheOperation(Step3)UsePinkCardImprovementIdeas(Step6)UseBlueCardErrors/Causes(Steps4-5)UseYellowCard操作的标准要素（步骤3）使用粉红色卡片错误/原因（步骤4-5）使用黄色卡片改进建议（步骤6）使用蓝色卡片CardwritingGuidelines卡片填写指南Writeoneelement,cause,orideapercard

每一卡片填写一个要素、原因或建议Bespecificandcomplete

内容明确且完整Useafullsentence,notaphraseoraword

使用整句，而非短语或单词Initialanddatecards

注明卡片的初始状态及日期Writesootherscanread

使其他人易于阅读Followcolorcodeonchart

遵循图表的颜色编码...AndInConclusion总结Mistakeproofinghelpsensureadherencetoreliablemethods.差错预防有助于保证可靠性方法的执行。Thefirstfivestepsofthemistakeproofingprocessareforanalysis.

差错预防过程的前五个步骤为分析阶段。SectionSix:第六部分ImprovementGuidelines&Examples改进方案&示例Functionofmistakeproofingdevices差错预防装置的功用Typesofdevices

装置的种类Levelsofintervention

干涉级别Examplesandredesigns

示例及重新设计FunctionofMistake

ProofingDevices差错预防装置的功用Mistakeproofingdevicesaresimpleandinexpensive.Theyareused:差错预防装置应该简单且便宜。它们可以用来：Topreventerrorsfromhappening防止错误的发生Todetecterrorsthathaveoccurred侦测已发生的错误Todetectdefectsthathaveoccurred侦测已发生的缺陷FastFeedback快速反馈100%Inspection100%检验MistakeProofing差错预防

3LevelsofPrevention预防的三个层次Inexpensive价格便宜Focused关注点突出EasytoImplement易于执行TeamBased以团队为基础Level1第一层EliminatetheError消除错误Level2第二层次DetecttheError侦测错误Level3第三层次DetecttheDefect侦测缺陷1.Guide/reference/interferencerodorpin导向/参考/干涉销2.Template模板3.Limitswitch/microswitch限位开关/微动开关4.Counter计数器5.Odd-part-outmethod显示剩余零件的方法6.Sequencerestriction序列限制7.Standardizeandsolve标准化和解决方案8.Criticalconditionindicator关键条件指示器9.Detectdeliverychute探测递送滑道10.Stopper/gate停止器/门11.Sensor传感器12.Mistakeproofyourmistakeproofingdevice:对你的防错装置进行防错设计Eliminatethecondition消除问题发生的条件Redesignforsymmetry对称性设计Redesignforasymmetry非对称性设计TypesofMistakeProofingDevices

差错预防装置的种类MPDevice1:差错预防装置1

Guide/Reference/InterferenceRods

导向/参考/干涉销MPDevice2:差错预防装置2

Template模板MPDevice3:差错预防装置3

LimitorMicroswitch限位开关/微动开关DepthMPDevice4:差错预防装置4

Counter计数器MPDevice5:差错预防装置5

Odd-Part-OutMethod显示剩余零件的方法MPDevice6:差错预防装置6

SequenceRestriction序列限制MPDevice7:差错预防装置7

StandardizeandSolve标准化及解决方案MPDevice8:差错预防装置8

CriticalConditionDetector关键条件指示器TypesofElementDetectors

探测器的种类Fluidelementdetectors流体探测器Pressurechangedetectors压力探测器Temperaturechangedetectors温度探测器Currentfluctuationdetectors波动探测器MPDevice9:差错预防装置9

Delivery(Detect)Chute递送（探测）滑道MPDevice10:差错预防装置10

Stopper/Gate停止器/门MPDevice11:差错预防装置11

Sensor传感器Beam&Fiber光束&光纤Area面积Positioning配置Displacement位移MetalPassage金属通路ColorMarking颜色标识Vibration振动TypesofSensors传感器种类MPDevice12:差错预防装置12

MistakeProofYourMistakeProofingDevice

对你的防错装置进行防错设计OtherPreventionTechniques其他预防技术Eliminate-ConditionMethod消除问题发生的条件OtherPreventionTechniques其他预防技术

RedesignforSymmetry对称性设计OtherPreventionTechniques其他预防技术

RedesignforAsymmetry非对称性设计DesignandCreateImprovements

设计并进行改善Step6步骤6

Identifythetypeofmistakeproofingdevicesrequired

识别所需的差错预防装置的类型Step7步骤7 Createappropriatedevicesandtesttheireffectiveness

制作适当装置并测试其有效性MistakeProofingReportForm

差错预防报告格式Team:团队__________________________Plant/Location:工厂/地域____________________Date:日期_______________________CurrentCondition:当前状态ImprovementUsingMistakeProofing:使用防错装置后的改进•Defect:缺陷________________________•SourceError:源头错误_______________•CosttoInstall:安装成本______________•TimetoInstall:安装时间____________•Remarks:备注•Operation:作业________________________•RedFlat:红旗________________MistakeProofingDevice:差错预防装置________________________________•LevelOne/EliminateAtSource:第一层次/从源头消除______________________•LevelTwo/DetectatSource:第二层次/在源头探测______________________•LevelThree/DetectBeforeNextOperation:第三层次/在下一操作前探测______...AndInConclusion总结Todevelopeffectivemistakeproofingsolutions,befamiliarwiththebasicdevicetypesandthethreelevelsofmistakeproofingprevention.制订有效的差错预防方案，需要熟悉基本的装置类型以及差错预防的三个层次。5WhyTargetForm“5个为什么”目标表Why?为什么Problem:Nocopiesarebeingmade问题：文稿没有被复印Why?为什么Cause:Thereisnopaper原因：机器没纸了Cause:Nopapersupplynexttothecopier原因：纸张没有及时补充Cause:Nopaperinthesupplycupboardforthisdepartment原因：该部门中的物料柜中没有纸。Cause:Someonedidn’torderpaper原因：没有人订购纸张。RootCause:Theremaybeanumberofreasonsatthispoint,someofwhichmayinclude:thereisnobudgetforofficesupplies,someoneforgottoorderpaper,nooneisassignedtoorderpaper,ourdepartmentusedmorepaperthannormalthismonthsoweranoutbeforeourregularorderwasreceived,etc.根本原因：就该问题而言，可能有若干种原因，其中包括：办公材料的供给没有预算、有人忘记订购纸张、订购纸张的任务没有委派到个人、该部门当月所用纸张超过正常水平，因此在正常订购送达之前出现缺纸、等等。Why?为什么Why?为什么Why?为什么案例练习Title:O-RingRemoval题目：O形密封圈的移除WhenremovingoldO-Ringsduringthedisassemblyprocessitisveryeasytodamagethebrassspoolvalves.Wedevelopedasimplemachinethatwouldcuttheo-ringwithoutdamageandalsospeeduptheprocess.Previousmethodsincludedsoakingincarburetorcleaner(hazardousmaterial)anddryremoval.Dryremovalcausesthemostdamagebutthecarburetorcleanerissmellyandrequiresrubberglovestohandleparts.在拆卸环节，当我们移除旧O形密封圈时，很容易损坏其中的短管阀。我们制作了一个简单的设备，使其能够在不发生损坏的情况下切开O形圈，并能够提高该过程的速度。在之前的方法中，需要先吸收化油器清洁剂（有害物质），并采用干法去除。干法去除是造成损坏的最大原因，同时，因为化油器清洁剂会产生异味，在处理过程中需要配带橡胶手套。Simplysetspoolvalveinholder,closetoggleclamp,pressblackbuttonando-ringsarecut!只需简单的将短管阀嵌入支架，合上肘节式价钱，按下黑色按钮，O形密封圈将会被切开！Title:MistakeProofing:AcidTank-SpringLoadedWaterFillValve题目：差错预防：酸液槽—弹力进水阀Theacidtankisheatedandconstantlyevaporateswater.Thetankmustnotbeoverfilledortheacidrunsoverthetopofthetank.Wehadanautomaticfillvalvebutitwasnot100%dependable.Whenwehadamanualvalve,theworkerwouldturniton,getdistracted,walkawayandthenthetankwouldoverflow.Nowwehaveaspringloadedvalvethatrequirestheworkertoholditopeninorderforthewatertoflow.Whentheworkerletsgo,thevalveshutsoff.Nomoreoverflowproblem.酸液槽需要加热并持续不断的蒸发水分，同时需要严防酸液溢出。我们已经有了一个自动进水阀，但是它并非100%可靠。如果我们安装手动阀门的话，操作者若在开启阀门之后走开的话，将有可能造成液体溢出。现在我们装上弹力进水阀之后，操作者需要握住阀门以注入液体。当操作者离开时，阀门将自动关闭，从而避免了液体溢出的问题。案例练习Title:Mistakeproofing:Fixtureimprovesquality,safety&efficiency

题目：差错预防：工装夹具能够提高质量、安全性&效率OldMethod:(Nofixture:Usevise&holdrollpinwithfingers)Assemblyoperation:assemblerollpinintofemalerodend.Itwasalwaysdifficultinsertrollpinhalfwayasrequired.原方法：（没有工装：使用手指拿握销辊）装配作业：将销辊装到摇杆头。将销辊按要求插入一半非常困难。Unsafeoperation非安全作业&poorquality质量低下Fixtureholdsrodend&operatorcanpeenrollpinwithpunch&holdexactdimension用工装固定摇杆头&操作者可用锤子敲击销辊&保证精确角度Theoperatorafterusingthenofixtureandvisemethod,hadanideaofaneasierandsaferwayofperformingthisassembly.Withhisideaandthehelpofatoolmaker,anewassemblyfixturewasimplemented.Thisideanotonlyimprovedqualityofthefinalassemblyofthissubassemblybutmadethisasaferoperationandimprovedtheefficiencyofthisoperation,byeliminatingnon-valueaddedtasks,costsavingo