suppliertrainingErrorProof福特防错培训

ErrorProofing

防错CFMAQ1&ExportSTA

Will-Zhou长安福特马自达Q1及出口供应商技术支持周全For

SuppliersIndex目录定义课程目标防错的好处何处需要防错缺陷与错误防错机会的识别防错装置示例DefinitionofErrorproofing防错定义“ErrorProofing”means“carelessmissproof”inthepossess

“防错”的意思是在生产过程中“防止粗心犯错”Purpose目的Thiscourseprovidesanintroductiontotheerrorproofingtoolsandprocesses,andthefundamentalsrequiredtoidentifyanddeveloperrorproofingsolutionsduringsiteassessments.课程提供了防错工具和防错过程，以及识别和开发防错基本要求。Participantswillleanhowtodeveloperrorproofingprocessesandidentifyopportunitiestoapplythesepractices.培训倾向于怎样在实践中识别防错的机会，并建立防错。Objectives目标Uponcompletionofthismodule,youwillbeableto:在完成这个单元之后，你将能够：IdentifyandpromoteErrorProofingtoeliminatecausesoferrorsanddefectsinaprocess.识别并提升防错机制以消除制程当中的错误和缺陷因素Applyconcepts,tools,techniquesandapplicationsofErrorProofing.防错的观念，工具，技巧和应用ErrorProofing防错Aprocessimprovementsystemthat:整个系统提升的过程是：preventspersonalinjury,预防人身伤害promotesjobsafety,提升工作安全preventsfaultyproducts,and预防产品失效和preventsmachinedamage预防机器损害Inspection检验Althoughitisnecessarytohaveefficientinspectionoperations,theyareoflittlevalueintheprocess.Eventhemostefficientinspectionoperationsaremerelyefficientformsofwaste.尽管有效的检验是必须的，但对生产的价值是很有限的。甚至最有效的检验也只不过是报废的形式不同罢了Inspectionplaysapassiveroleinproduction-byitselfitcannotreducedefects在生产过程中，检验始终是被动的，不能降低缺陷BenefitsofError-Proofing防错的好处Enforcesoperationalproceduresorsequences强制操作程序或者顺序Signalsorstopsaprocessifanerroroccursoradefectiscreated如果错误发生或产生不良就报警或停止生产Eliminateschoicesleadingtoincorrectactions消除因选择导致的错误行动CostAnalysisofError错误成本分析Costoftimetoworkondefectiveparts针对缺陷零件的时间成本Costofallmaterialsused使用的材料成本Costoftimespentinrework返工花费时间成本Costofmaterialusedforrework返工材料成本Costoftimespentinspectingdefectiveparts检验缺陷零件成本Lostproductiontimespentondefectiveparts停产时间成本Impactoflowercustomersatisfaction客户满意度降低的影响Impactoflowerworkermorale员工士气降低的影响NeedForError-Proofing需要防错Humanerrorisanaturaloccurrence;allhumansmakeerrors.Humansarelimitedby:错误是自然发生的，所有人都避免不了。我们会被以下因素限制：Vision视觉Hearing听觉RepetitionAbility重复能力WhatistheoccasionofErrorProofing?

什么场合需要防错1.CanmakeahumanerrorevenExperiencedprofessionals.能让有经验的专业人员出错2.Itisdifficulttodetecttheerrorinatthefinalinspection.在最终检验中很难发现的错误3.Needmorecosttoscrapthecompletedmodule.返工维修成本比较高Defectsvs.Errors缺陷对错误ToenhancetheunderstandingofError-Proofing,itisimportanttounderstandthedifferencebetweenadefectandanerror理解缺陷与错误的差异对提高对防错的理解来说是很重要的Thefollowingslideswillclarifythispoint以下的幻灯片会说明这一点DefinitionofaDefect缺陷的定义ProcessFlow流程ERROR错误DEFECT缺陷ToNextProcess下道工序Tobeadefect何为缺陷:Theproductmusthavedeviatedfromspecifications产品超规Theproductdoesnotmeetcustomerexpectations产品未达到客户要求CommonDefectCategories

常见缺陷类型Damagedparts/product产品或零件损坏Reversedparts/product装反Foreignmatterpresent外部问题Mismatchedparts错装Misalignedparts零件位置错位Cannotbeassembled无法装配Inconsistenttestresults/testfailure测试结果或测试故障不一致Badincomingmaterial来料不良Wrongmaterial/parts材料或零件问题Wrongorinconsistentdimensions尺寸问题Other....?其他…?DefinitionofanError错误的定义Anerrorisanydeviationfromanintendedprocess.错误是指任何不符合过程的要求Occurswhenanyconditionnecessaryforsuccessfulprocessingisimproperorabsent在一个成功的具备相关条件过程当中出现的不适当或者缺少的环节Alldefectsarecreatedbyerrors所有缺陷都是因为错误导致Notallerrorsresultindefects并非所有的错误都导致缺陷ProcessFlow流程ERROR错误POSSIBLEDEFECT可能导致缺陷ToNextProcess下道工序TopTenCommonErrors最常见的前10种错误Processingomissions制程冗长Processingerrors过程错误Errorinsettinguptheworkpiece错误的设置Assemblyomissions(missingparts)组装冗长(容易漏件)Inclusionofimproperpart/item包含不合适的零件/物品Wrongworkpiece错误的加工件Operationserrors操作错误Adjustment,measurement,dimensionalerrors调整，量测，尺寸错误Errorsinequipmentmaintenanceorrepair错误的设备维护或维修Errorinpreparationofblades,jigs,ortools错误的操作夹具或工具DefectIdentificationExercise缺陷识别练习RedFlagConditions红旗的条件Aconditioninthemanufacturingprocesswhichcommonlyprovokeserrors制程中容易产生错误的条件RedFlagConditions红旗的条件Adjustments调整Tooling/toolingchanges工具/制具的变更Dimensions/specifications/criticalconditions尺寸/规格/关键条件Many/mixedparts大量的/混合的零件Multiplesteps多重的步骤Infrequentproduction很少生产的产品Lackofaneffectivestandard没有有效的标准Symmetry对称的Asymmetry不对称Rapidrepetition迅速重复的High/extremelyhighvolume非常高产量Environmentalconditions:环境条件materials/processhandling原料/过程操作foreignmatter外部问题poorlighting灯光不好Housekeeping管理保养RedFlagOne红旗1Adjustments调整17drillholes,PCD148mmlength1817个钻孔PCD148mm长181Improperposition不合适的位置referencessmallplatemediumsizedplatelargeplateUpperedgewasusedasapositioningreference上部的装置可以限位Tooling/ToolChange工装的变更2RedFlagTwo红旗2Iseveryholetherightdepth?每个孔的深度都正确么RedFlagThree红旗3DimensionsNarrowspecs/Criticalconditions尺寸/规格窄/关键条件3RedFlagFour红旗4Didyouforgetsomething?你忘了什么没有？Many/PartsMixedParts很多/混合零件4RedFlagFive红旗5MultipleSteps多重步骤5WhichstepamIonnow?我在哪一步？RedFlagSix红旗6InfrequentProduction很少生产的产品6RedFlagSeven红旗7IneffectiveStandardsorNoStandards无效的标准或没有标准7Howmanygointhiscontainer?这个箱子可以装多少？extraholes外部的孔Plug插头CORRECT正确INCORRECT不正确RedFlagEight红旗8Symmetry对称8Asymmetry不对称9ramchassisWrong错误Right正确onegroove凹槽RedFlagNine红旗9RedFlagTen红旗10nextprocessfromautomaticwelding自动焊接chuteshaftomittedweldedcorrectlyRapidRepetition迅速重复10RedFlagEleven红旗11Upsidedown倒置Workpiece加工件High/VeryHighVolume高产量11reelstand线盘架ForeignMatter外部因素TensionDevice绷紧装置dimensionalVariation尺寸变异tomachinewirestock线盘RedFlag12红旗12EnvironmentalConditions环境条件12RedFlagConditionExerciseIdentifytheRedFlagconditionsinthefollowingexamples在以下事例中识别标红旗的条件ExampleOne事例1viewingAngle观察角度buttonholder纽扣固定Button纽扣buttonsshouldbeevenlyspaced纽扣之间应距离均匀ExampleTwo事例2–Theprocessorthegauge?过程或者量具Whichiswrong?什么出了问题？ExampleThree事例3Thispartishiddenandcannotbeseenintheinspectionprocess该零件被隐藏，检验过程看不到ExampleFour事例4leversA-D控制杆A-Dpushbuttons推动按钮ABCDClosedbox–isitemptyorfilled?封闭的盒子-空的还是满的ExampleFive事例5ExampleSix事例6traceshieldcase护罩circuitboard电路板mountingslot安装槽symmetricalmountingtabs对称的支撑脚canbemountedbackwards能被装反aaExampleSeven事例7partsmoldedtogether共模零件PartA(notched)零件A(有凹槽)PartB(nonotch)零件B(无凹槽)ErrorProofingWorksheet防错工作表TeamMembers小组成员:ErrorProofingImplementationWorksheet防错执行工作表ErrorProofingAspects防错的方方面面Physical-installEPdevices物理的-安装防错装置Operational-ensurecorrectprocedure,sequence,orexecution操作的-确保正确的程序，顺序或者执行Philosophical-empowermentofworkforce哲学的-劳动力的授权FunctionOfErrorProofingDevices

防错装置的功能Error-proofingdevicesshouldbesimpleandinexpensive.Theyareused:防错装置应该简单便宜，被用于：Topreventerrorsfromoccurring预防错误发生Todetecterrorsthathaveoccurredandpreventdefects查明错误的发生并预防缺陷Detectdefectsthathavebeenmadebeforeitmoveson在缺陷扩大前探测出来FastFeedback快速回馈100%Inspection100%检验PreventionVs.Inspection/Correction

预防对检验/纠正Error-ProofingApproaches防错的方法Prevention预防Preventserrorsfromoccurringordefectsfrombeingcreated

从事故当中预防错误，从不良品当中追寻原因

Inspection/Correction检验/纠正Detectsthatadefecthasbeencreatedandinitiatesacorrectivemeasureinstation探测已经存在的缺陷并开始纠正Error-ProofingDevices防错装置CommonElectricalDevices常用的电器装置CommonMechanicalConcepts常用的机械观念LimitSwitch限位开关ProximitySwitch触发开关Microswitch微动开关Definepartpositioningforaprocess定义零件位置AllowonlycorrectpartstopassforfurtherProcessing只允许正确的零件通过Enforcecorrectassembly强迫正确的组装TypesOfErrorProofingDevices

防错装置的类型Guide/reference/interferencerodorpin指南/参考书/干涉棒/销子Template模板Limitswitch/microswitch

限位/微动开关Counter

计数器Odd-part-outmethodSequencerestriction

顺序约束Standardizeandsolve

标准化Criticalconditionindicator判断条件指示器Detectdeliverychute探测斜道Stopper/gate限位器Sensor传感器MistakeproofyourErrorProofdevice防错装置Eliminatethecondition排除条件Redesignforsymmetry重设对称Redesignforasymmetry重设非对称Case示例Preventincorrectboardsetting

(Hiroshima)防止板方向装错Correctdirectionofthesetting纠正安装方向Wrongdirection(upsidedown)错误方向(上下装反)Addtheplatetosettheboardincorrectdirection.增加限位钢板Operatorcannotsettheboard.操作者不能安装Case1Preventincorrectmatchingboardandhousing.(Cervantes)防止板和机架