防误措施（PPT 26）.PPT

1、MISTAKE-PROOFING防误措施,ACEElements,QCPC,RootCause/CorrectiveAction,Passport,MistakeProofing,MarketFeedbackAnalysis,6S,QualityClinicActivity,TPM,ACE内容,质量诊断程序图表,根本原因修正行动,设计开发通行证,防误措施,市场反馈分析,6S,质量诊断行动,全面生产性维护,ACEElements,EngineeringNewProducts,Processes&SystemsPassport-Systematicmethodforreview/approvalo

2、fnewdesigns,StandardMethodProcessManagement-Meanstoidentify&mapkeybusinessprocessesStandardWork-Repeatableprocessesthatareeffectiveandefficient,QualityImprovementMethodsQCPC-Simpletooltoidentifyproblemsandinefficiencies(turnbacks)MFA-DatasummariesthatdisplayhowcomponentsperforminfieldRootCause-Metho

3、dtodrivetothetruesourceofproblems,StandardEnvironmentNew6S-WorkplaceorganizationandvisualcontrolTotalProductiveMaintenance-Continuouslyimprovingequipmenteffectiveness/availability,Mistake-Proof-Creationofdevicesthatensureataskisalwaysdonecorrectly,ACE内容,开发新产品、程序和系统设计开发通行证-检查/批准新设计的系统方法,标准方法程序管理识别并展示

4、重要商业程序的方法标准化作业-可重复的有效程序,质量改进方法质量诊断程序图表-识别问题和低效率（返工）的简单工具市场反馈分析-展示组件是怎样工作的数据摘要根本原因-发现问题的真正来源的方法,标准环境新6S-工作场地组织和直观控制全面生产性维护-不断地改善设备的有效性和可用性,防误措施-确保任务总能正确完成的设备的措施,Increaseprofitabilitybyeliminatinginadvertentmistakes消除无谓的错误可增加利润率Increaseproductivitybyreducingwastedtime减少浪费的时间可提高生产力Improvecustomersatisf

5、actionandqualitybyeliminatingescapes消除逃脱可提高客户满意度和质量Increasereliabilitybycontinuouslyimprovingproducts,servicesorprocesses不断改进产品、服务或程序可提高信誉,BenefitsofMistake-Proofing防误措施的好处,Theyarenotthesamething!MistakesCauseDefects.他们是不同的！错误导致过失,Mistakesvs.Defects错误vs过失,Mistake错误,Defect过失,Pumpingdieselfuelintoyour

6、gastank.将柴油加入汽油箱,Runningaredlight.撞红灯,Forgettingtounplugyouriron.忘记拔掉电熨斗的插头,Placingthe“original”inyourcopierfeeder“facedown”.将原件放进了复印机的进纸处并正面冲下,or,Misunderstandingrequirements误解了要求Skippingaprocesssteportasks漏掉了一个工作步骤Performingprocessstepsincorrectlyorinthewrongorder未正确地或以错误地顺序执行程序步骤Contamination污染,M

7、ostCommonMistakes最常见的错误,Leavingoutapartorapieceofinformation漏掉了一个零件或一条信息Adjustmentandmeasurementmistakes调节和测量错误Timingmistakes定时错误Usingthewrongpart,toolorinformation使用了错误的零件、工具或信息,Mistake-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalwaysdonecorrectly.防误措施是指运用智慧和独创性发展出一个能确保

8、任务总是能正确完成的设备的方法。,Mistake-Proofing防误措施,Itremovesuncertaintyfromthesituationswhereerrorsaremostlikelytooccur,suchas:它去除了最可能发生错误的情形中的不确定性，如：Repetitivetasks重复性的任务Complexinstructions复杂的说明书Calculations/Adjustments计算/调节Look-alikeparts相似的零件,WhydowedoMistakeProofing?为什么我们要采用防误措施？,Topreventturnbacksandcustome

9、rescapesfromrecurring,sincethecosttofixaproblemincreasesrapidlythelateritisfound:为防止缺陷和客户逃脱情况再次发生，因为问题发现得越晚所花的费用就会迅速增加：,Ifadefectoccurshere如果在这儿发生过失,anditsfoundhere,并在这儿被发现，itcosts:就要花费：,Rework,repair,scrapandescapescostUTC$148millionperyear.Warrantyexpensescostusanother$600millionperyear.Thecostofl

10、ostcustomerloyaltyduetoescapesisimmeasurable.返工、修理、废弃和逃脱每年要花掉UTC1.48亿。保修费用每年花掉我们另外6亿。由于逃脱而丧失了客户的信任的损失则不可计算。,Mistake-Proof防误措施theDesign设计Redesigntheproduct重新设计产品Eliminatethemistakecondition消除犯错误的条件Redesignforsymmetryorasymmetry重新进行对称或不对称设计Changethematerials改变材料Changecomponenttype,characteristicsorsup

11、plier改变组件的类型、特征或供应商,2ApproachestoMistakeProofing预防错误的2个途径,Mistake-Proof防误措施theProcess加工Changeoraddtooling改变或增添工具Changeprocesssteps改变加工步骤Adduseofchecklists,templatesorgages增加使用清单、模板或测量仪Implementcontrolcharts执行控制图表,ProcessDescription:Makingapotofcoffee程序描述：泡一壶咖啡,ExampleofMistake-ProofingtheDesign防误措施范

12、例设计,BeforeImprovement:改进前：Waterneededtobemeasuredforeachpotofcoffeeoftenresultingincoffeethatwastooweakortoostrong泡前每壶咖啡的水量都要测量常常导致咖啡过淡或过浓。,ProcessDescription:Makingapotofcoffee程序描述：泡一壶咖啡,ExampleofMistake-ProofingtheDesign防误措施范例设计,AfterImprovement:改进后：Coffeemakerwasredesignedtomeasureandaddtheprecis

13、eamountofwaterfromawaterbottle重新设计咖啡机以使每次从水瓶中加入的水的量都一样多,ProcessDescription:Alabelispastedintoarecessinamoldedchassis程序描述：将标签贴在底盘的凹槽内,ExampleofMistake-ProofingtheDesign防误措施范例设计,BeforeImprovement:改进前：Therecessandthelabelwerebothrectangular.Thelabelcouldbegluedinupside-down.凹槽和标签都是长方形。标签可能会贴反。,AfterImp

14、rovement:改进后：Anotchwasmadeinthecornerofthelabel,andintherecessofthechassis.Incorrectmountingiscompletelyeliminated.在标签和凹槽的一角做一个切口。就能完全防止错误发生。,ExampleofMistake-ProofingtheDesign防误措施范例设计,ProcessDescription:Installslidesintoaslideprojector程序描述：将幻灯片装入幻灯机中,BeforeImprovement:改进前：Aresomeslidesupsidedown?有一

15、些幻灯片装反了吗？,AfterImprovement:改进后：Topedgeofeachslidemarkedwithareddot.每张幻灯片的上边都有一红点。,ExampleofMistake-ProofingtheDesign防误措施范例设计,ProcessDescription:Torquinganumberofboltsrecesseddeepinacavity.程序描述：将大量螺栓拧进空腔深处的凹槽内,BeforeImprovement:改进前：Thesocketextensionrequiredtoreachtheboltscausednicksandscratchesinthe

16、paintedsurfacesthatitcontactedduringassembly.在操作的过程中，用来拧螺栓的拧杆柄会对油漆表面造成刮伤。,AfterImprovement:改进后：Arubberhosewasinstalledoverthesocketextensionandwasspecifiedontheworkinstructions.一个橡皮管被装在拧杆柄上并在工作说明书上有详细说明。,Mistake-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalwaysdonecorrect

17、ly.防误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。,Mistake-ProofingisntWords!防误措施不是文字！,Word“Solution”文字“解决方法”,Problem:The“OneDay“employeebadgeformasksforbadge#andclock#.Employeesoftenwritetheirclock#inthebadge#spot.问题：“一日”雇员的证件表格要求填写证件号和钟点号。雇员常将钟点号填在证件号的位置。,Badge#证件号,Clock#钟点号,(filledoutbyEmergencyServices)（

18、由紧急服务部填写）,(filledoutbyemployee)（由雇员填写）,Guidepinsorinterferencepins向导图钉或干涉图钉Templates模板Partkitsusingshadowboxing使用能防止错误的零件包Limitswitches限制阀,MostCommonTypesofMistake-ProofDevices最常见的防误设备,Counters计算器Alarms闹钟Weightsandmeasures称重秤和测量仪Checklists清单Controlcharts控制图表,Mistake-ProofingProcessChanges防误码程序的改变,Im

19、provetheprocess!改进程序！Simplify简单化Reducesteps,parts,forms,dataonforms,numberofprocesssteps,etc.减少步骤、零件、表格、表格上的数据、加工步骤的数量等。Consolidate/Co-Locate巩固/共用Bringoperationsclosertogether,reducework-in-process(WIP)使操作变得更紧凑，减少过程工作（WIP）Standardize标准化Maketheprocessvisual使程序可见Moveresponsibilityandauthoritydowninthe

20、organization将责任和权利下放给组织,Try-Storming(vs.Brainstorming)尝试风暴（对头脑风暴）Involvetherightpeople让合适的人参与Walktheprocessandgetthefacts检验程序并获得事实Dontjustsitandthinkaboutsolutions.TRYTHEM!不要只是坐在那儿想解决问题的方法去尝试！,CreatingMistakeProofing创建防误措施,The“NastyTest”(vs.the“Solution”)“恶心的试验”（对“解决方法”）Whenyouthinkyouvegotthebestso

21、lutionTRYTOMAKEITFAIL!当你认为你已找到最佳解决方法时试着去让它失败Involveallusers让所有使用者参与Mistake-proofdevicesmustbe100%effectiveatdealingwithaparticularmistake在处理特殊错误时防误设备必须100%有效Ifnot,theywillbeignored如果不能，就应放弃Ensurethemistake-proofdoesntcreateanotherproblem确保防误措施不会引起其它问题,TestMistakeProofingwiththe“NastyTest”用“恶心的试验”来验证

22、防误措施,Formally,aspartoftheQCPC/MFAProcess形式上的，作为QCPC/MFA程序中一部分,WhendoyoudoMistake-Proofing何时采取防误措施,2)Real-time,wheneveryounoticeamistaeoccurringorthepotentialforamistake实时的，无论何时你发现一个错误或有出错的可能性,Thereare3LevelsofMistake-Proofingbasedoneffectivenessandspeed:防误措施有三个基于有效性和速度的等级：LevelIII:Detection等级三：发现Lev

23、elII:Alert等级二：警告LevelI:Prevention等级一：防止,ThreeLevelsofMistake-Proofing防误措施的三个等级,LevelIII,Detect:AllowsyoutodetectyourMistakeafterithasoccurred.(1point)等级三，发现：在已经发生之后发现错误Checklists清单Computerbeeps电脑提醒ManuallyactivatedSpellCheck手工拼写检查LevelII,Alert:AlertsyouastheMistakeishappening.(2points)等级二，警告：当错误正在发生时提醒你Sensors,alarms,controlcharts传感器、闹钟、控制图表Counters计算器AutomaticSpellCheck自动拼写检查LevelI,Prevent:PreventsyoufrommakingtheMistake.(3points)等级三，防止：防止你犯错误Eliminatingthemistakecondition(changingthedesign)消除犯错条件Automation自动控制Spelling“Auto-corrector”拼写“自动更正器”,ThreeLevelsofMistake-Proofing防误措施的三个