ErrorProofing

防錯ErrorProofing

防錯Topics-ErrorProofingTraining

Topics-ErrorProofingTrainiTopics主題ObjectivesoftheTraining培訓的目的WhatandWhyofErrorProofing什么是防錯，怎樣進行防錯ApplicationofErrorProofing防錯應用IdentifyOpportunitiesforErrors防錯時機的確定OverviewofFailureModeandEffectsAnalysis(FMEA)失效模式和效果分析總括ErrorProofingOptions防錯的選擇Prevention&DetectionThroughPokaYokeDevices通過PokaYoke進行預防與探測MovetoTheNextLevel轉(zhuǎn)入下一級ABenchmarkWithinEaton伊頓內(nèi)部標準Summary概要Topics主題ObjectivesoftheTraiObjectivesoftheTraining

培訓的目的UnderstandWhatIsErrorProofingandWhatItCanDo了解什么是防錯和防錯能做什么UnderstandthePrinciplesofErrorProofing了解防錯的原理LearnHowtoApplyErrorProofingtoProductsandProcesses了解怎樣對產(chǎn)品及工藝過程應用防錯LearnAboutthePokaYokeDevicesandSystems了解PokaYoke裝置和系統(tǒng)LearntheProcessofImplementationandContinuousImprovements了解實施防錯的過程和持續(xù)改進的過程ObjectivesoftheTraining

培訓的WhatAreYourExpectations?

你們的期望是什么？WhatAreYourExpectations?

你們WhatandWhyofErrorProofing

什么是防錯以及為什么要防錯WhatandWhyofErrorProofingDefinition

定義ErrorProofingIsaSystematicApproachforAnticipatingandDetectingPotentialDefectsandPreventingThemFromReachingtheCustomer(InternalorExternal)防錯是一種預測及探測潛在缺陷以及阻止缺陷影響客戶的體系方法(內(nèi)部防錯和外部防錯)Definition

定義ErrorProofingIsErrorProofingbyOtherNames

以其他名稱進行防錯FoolProofing防止愚蠢行為IdiotProofing防止白癡行為MistakeProofing防止錯誤行為FailSafing安全失效PokaYokeZeroQualityControl(ZeroDefects)零質(zhì)量控制（零缺陷）DesignforManufactureandAssembly制造和裝配的設計LetUsNotArguetheMeritsofTheseNamesLetUsDecideWhatWeWanttoAchieve我們不要爭論這些名稱,讓我們決定想要完成什么?DemoralizingTerms防錯術語ErrorProofingbyOtherNames

CharacteristicsofErrorProofing

防錯的特點ProactiveIdentificationandPrevention前期識別及預防PreventFirst首先進行防錯DoNotAllowDefectFromGoingFurther其次不準許缺陷進一步發(fā)展IntentionallyDesigned,NotHappenstance設計錯誤,非偶然錯誤.AttheSource-ClosetotheOrigination錯誤的來源_接近發(fā)源地.InexpensiveFirst首先成本不高TransparenttotheOperator操作者很容易發(fā)現(xiàn)AbsolutelyReliable錯誤根源查找絕對準確AMeanstoAchieveZeroDefectProduct一種達到0缺陷產(chǎn)品的方法CharacteristicsofErrorProofDefectsinProductsAretheImperfections(orFaults,orFlaws,orBlemishes,orShortcomings,orFailings,orDeficiencies)

缺陷是指產(chǎn)品里的不完整性(或者故障,或者裂紋,或者瑕疵，或者短處，或者過失，或者不足)ResultingFromErrors錯誤產(chǎn)生的結果ErrorsAreHumanOversights(orFaults,orBlunders,orBoo-boos,orSlip-ups,orInaccuraciesorMiscalculations)ThatCauseDefectsinProducts錯誤是人為疏忽(或者過錯,或者失誤,或者低級錯誤，或者失敗，或者精度失誤或者計算失誤)，這些引起產(chǎn)品的缺陷。DefectsandErrors

缺陷和錯誤SO,ErrorsCauseDefectiveProducts!!所以,錯誤導致有缺陷的產(chǎn)品產(chǎn)生!!DefectsinProductsAretheImWhyAreErrorsMade

為什么會導致錯誤AnyProductIsaResultofNumerousDecisionsMadeandActionsTakenbyHumanBeings,During:任何產(chǎn)品都可以在下述一系列人為行為中產(chǎn)生錯誤：ProductDesign產(chǎn)品設計ProcessDesign過程設計EquipmentDesign設備設計ComponentFabricationProcesses零件加工過程ProductAssemblyProcesses產(chǎn)品裝配過程InspectionProcesses檢驗過程PaperworkGeneration程序行程過程Etc.等等AndHumanBeingsareFallibleorImperfect人是容易犯錯或不完美的WhyAreErrorsMade

為什么會導致錯誤AnSOMEExamplesofDefects

屬于缺陷的一些例子WrongorInappropriateMaterial錯誤或不適合的材料WrongorNon-functioningComponents錯誤或者沒有功能的零件WrongDimensionsorTolerances尺寸或公差錯誤MissingComponents零件漏裝ForeignMatters,Contamination雜質(zhì)物質(zhì),污穢物DamagedProductorComponents受損產(chǎn)品或零件WrongPaperwork,orWrongProductShipped程序錯誤或者運輸了錯誤的產(chǎn)品Non-functioningorMalfunctioningProduct沒有功能的產(chǎn)品或者是故障產(chǎn)品WrongShipping,orWrongBilling運輸錯誤或者是填單錯誤SOMEExamplesofDefects

屬于缺陷的SOMEExamplesofCausesofDefects

導致缺陷的一些例子PoorDesignDecisions設計比較乏味OmittedorWrongProcessing過程疏忽或過程錯誤Missing/ExtraPartsorWrongParts漏裝/多裝了錯誤的零件OmittedorWrongAdjustment/Testing遺漏調(diào)整/測試或調(diào)整/測試過程錯誤WrongEquipmentSetuporLossofSetup設備設置錯誤或沒有進行設備設置WrongMaterial,ComponentsorAssemblies材料，零件或者裝配錯誤WrongCommunication,Instructions,Procedures,orMethods錯誤的信息，指令，程序，或者方法Inexperience,LackofTraining,WrongTraining,LackofRetraining缺乏經(jīng)驗，缺乏培訓，培訓錯誤，缺少再培訓SOMEExamplesofCausesofDefSOMEExamplesofResultsofDefects

缺陷導致的結果示例

MalfunctionorNon-functioningProduct有故障或者缺乏機能的產(chǎn)品Inconvenience,Discomfort,Injury,Death麻煩，不便，傷害，死亡Delays,Cancellations延期，取消FinancialLosses財政損失LossofUseorProductivity效用或者生產(chǎn)力的缺乏DamagetoCustomer’sProperty損害客戶的利益LiabilitiesandLawSuites負債和法律問題LossofReputationandBusiness名譽和業(yè)務受損SOMEExamplesofResultsofDeSOMECausesofHumanErrors

導致人們犯錯誤的一些原因Forgetfulness,LossofConcentration,LackofAttentionorDivertedAttention健忘，不集中，缺乏注意力或者轉(zhuǎn)移注意力MisunderstandingorLackofUnderstanding誤會或者缺乏理解LackoforImproperExperience/Training缺乏經(jīng)驗/培訓或者不正確的經(jīng)驗/培訓LackofStandardization缺乏標準IntentionalorWillfulError有意圖的或者惡意的錯誤WrongorDelayedDecision決定錯誤或拖延LimitedorLackofSensoryCapability(e.g.,Smell,Color,Touch)有限的或者沒有感官能力（例如，嗅覺，色彩，觸覺）LackofApplicationofCommonSense缺乏運用常識判斷的能力SOMECausesofHumanErrors

導致ErrorProofinginaFewWords

預防錯誤的一些方法“…occurrenceofdefectwastheresultofsomeconditionoraction,andthatitwouldbepossibletoeliminatedefectsentirelybypursuingthecause.Thecausesofdefectslieinworkererrors,anddefectsaretheresultsofneglectingthoseerrors.Itfollowsthatmistakeswillnotturnintodefectsifworkererrorsarediscoveredandeliminatedbeforehand.”缺陷的產(chǎn)生是一些環(huán)境或者行為導致的結果，但是完全有可能通過查找原因排除缺陷。缺陷原因在于工人，缺陷是因為工人忽視錯誤而產(chǎn)生的。如果工人能及時的發(fā)現(xiàn)錯誤并且消除錯誤，就不會導致缺陷的產(chǎn)生。ShigeoShingoErrorProofinginaFewWords

WhyErrorProof?

為什么防錯？99.9%ErrorFreeCouldResultin99.9%沒有錯誤導致什么結果2,000,000DocumentsLostbyIRSIRS缺少2，000，000檔案16,000PiecesofMailLostEveryDay每天丟失16，000郵件22,000WronglyDebited/CreditedChecksPerHour每個小時都會發(fā)生22，000寫錯借方和貸方的支票1,314WronglyConnectedPhoneCallsPerMinute每個小時都會發(fā)生1，314起電話占線20,000IncorrectDrugPrescriptionsPerYear每個小時都會發(fā)生20，000起用錯藥物的情況12NewbornBabiesGiventoWrongParents12個小孩被父母抱錯2UnsafeLandingsEveryDayatO’HareAirport每天都會有2起飛機不安全著陸32,000MissedHeartbeatsPerPersonEachYear每年每個人都會有32，000Is99.9%GoodEnough???99.9%夠不夠好???WhyErrorProof?

為什么防錯？99.9%ETheErrorsThatBecameHeadlines

錯誤變成頭條TitanicSinking泰坦尼克號的沉沒ChallengerBoosterRocketSealFailure挑戰(zhàn)者號火箭發(fā)射失敗MarsLandingModuleCrash火星升空失敗墜毀HubbellTelescopeReflectorErrorHubbell望遠鏡反射誤差ExxonValdezOilSpillExxonValdez石油泄露ChernobylNuclearPowerPlantMeltdownChernobylNuclearPower設備報廢ReleaseofMethylIsocyanate(MIC)FromUnionCarbidePlantinBhopal,India甲基異丙酮從Bhopal,India,MIC碳化物廠房泄露ThreeMileIslandNuclearPlant三英里小島的核廠房FirestoneTiresonFordExplorer福特車上的耐火石探測器TheErrorsThatBecameHeadlinErrorProofingandLean防錯及精益生產(chǎn)LeanInsistsonOnePieceFlow精益生產(chǎn)強調(diào)單件流IfThatOnePieceIsDefective,FlowIsDisrupte如果單件流有缺陷,流向就會被打斷LeanInsistsonLimitedInventory精益生產(chǎn)強調(diào)有限庫存IfThatInventoryIsDefective,theLinesCanSto如果庫存有缺陷,線路就會停止LeanMeansEliminatingWaste精益是指消除浪費DefectsandCorrectiveActionsAreWast缺陷以及糾正措施是針對浪費LeanRequiresThatEquipmentIsReadyWhenNeededandFunctionsWellAsLongAsNecessary精益生產(chǎn)要求當需要設備時,設備馬上可以用,且功能完好ErrorProofingtheTools,Fixtures,Setups,MethodsandDocumentsEnsuresEquipmentEffectiveness刀具,卡具,啟動,方法以及文件等防錯以確保設備的有效性ErrorProofingandLean防錯及精益生產(chǎn)ErrorProofingExamples

inEverydayLife

在每天生活中防錯的一些例子Home家里AutomaticShutoffIrons全自動熨斗GroundFaultCircuitBreakersforBathroomorOutdoorElectricCircuits浴室或室外電氣線路的接地保護PilotlessGasRangesandHotWaterHeaters油量表以及熱水器Child-ProofCapsonMedicineBottles藥瓶上保護小孩安全的瓶蓋Retail零售Tamper-ProofPackaging錐型防錯包裝BarCodingatCheckou檢驗時的條碼Office辦公室SpellCheckinWordProcessingSoftware在Wordword處理軟件中進行拼寫檢查Verifying“Doyouwanttodelete?”WhenPressthe“Delete”ButtononYourComputer當按刪除按鈕時電腦會詢問你“要刪除嗎”?Factory工廠DualPalmButtonsandOtherGuardsonMachinery

設備上使用兩個按扭及其他保護裝置BarCoding條碼Lock-Out/Tag-Out

鎖緊/打開標簽ErrorProofingExamples

inEvErrorProofingExerciseNo.1

防錯練習的第一部分FormTeamsofTwo兩個一組ListAsManyExamplesofErrorProofingAsYouCan,FromEverydayLife從你每天的生活中,列出你能作到的關于防錯的許多例子10Minutes10分鐘ErrorProofingExerciseNo.1

ApplicationofErrorProofing

防錯的應用ApplicationofErrorProofing

EssentialStepsforErrorProofing

防錯的基本步驟IdentifyOpportunitiesforErrors(CriticalFactors)識別防錯的時機(關鍵因素)PrioritizePotentialErrorsforErrorProofing對潛在的錯誤加以，區(qū)分進行防錯AbsolutelyMustPreventtheDefects必須完全的防止錯誤ProvideContainmentandStudyFurther預防錯誤和深入研究MayBeTolerated,WithinPredefinedLimits在計劃的范圍內(nèi)進行防錯IdentifyRootCausesoftheErrors識別錯誤根源DevelopandEvaluateErrorProofingOptions開發(fā)和評估防錯方案Selectand“Design”theErrorProofingSystem選擇和設計防錯系統(tǒng)Implement-Plan,Install,Document,Train,Monitor實施防錯－設計反錯，安裝防錯,編制防錯文件,培訓,監(jiān)控PeriodicallyAssessthePerformanceandImprove對防錯情況進行定期評審及改進EssentialStepsforErrorProoManufacturingProcesses制造過程ProductQuality產(chǎn)品質(zhì)量ProcessDesign過程設計ProductDesign產(chǎn)品設計WhatistheRightTimetoErrorProof??

正確的防錯時間是什么時間?100:110:11:1AsEarlyAsPossible及早發(fā)現(xiàn)ManufacturingProcessesProductWhyErrorProofEarlyDuring

NewProductDevelopment

為什么在新產(chǎn)品開發(fā)期間防錯Costof“Fixing”theDefects“修理”缺陷的成本ConceptDevelopment觀念開發(fā)PreliminaryDesign初步設計DetailedProductDesign詳細的產(chǎn)品設計CustomerSupport客戶支持Industrialization產(chǎn)業(yè)化Production生產(chǎn)ProcessDesign過程設計Costof“Fixing”設備的花費MultipliesWithLifeCycleStages整個過程當中的多項防錯StagesofProductLifeCycle產(chǎn)品生命周期中各個階段WhyErrorProofEarlyDuring

WhyErrorProofEarly

DuringProcessing

在處理期間為什么要盡早防錯Costof“Fixing”theDefects設備成本失效IncomingParts外協(xié)件AfterCompletingtheProcess過程完成之后AttheEndoftheLine產(chǎn)品最終離開生產(chǎn)線AfterDeliverytoCustomer交付給客戶之后FinalTest最后檢驗Costof“Fixing”IncreasesWithProcessSteps隨著程序步驟增長修復錯誤成本增長StepsofProductProcessing產(chǎn)品處理的步驟Reject&Return廢棄件NoDelay沒有拖延Reject&Scrap廢棄件&廢品MinorDelay稍微拖延Reject&Scrap/Rework廢棄件&廢品/返工RescheduleSomeDelay進度稍有拖延SignificantRework/ScrapAddtotheProductionScheduleDelayedDeliveries重要的返工/廢品影響生產(chǎn)進度及產(chǎn)品交付WarrantyCostsAdministrativeCostsLiabilitiesReputationMarketShareLoss擔保成本及管理成本增加,導致市場份額損失WhyErrorProofEarly

DuringErrorProofingExerciseNo.2

防錯訓練的第二部分FormTeamsofTwo兩個一組DiscussandAgreeonOneExampleofProductDesignorManufacturingProcesstoAnalyze討論一個產(chǎn)品設計或制造工藝的例子,并進行分析Identify鑒別ErrorProofingImplemented防錯實施EstimateCost/QualityImpact消除成本/質(zhì)量影響OR或者ErrorProofingOpportunitiesMissed喪失防錯良機EstimatetheCost/QualityImpact消除成本/質(zhì)量影響ListLessonsLearned學到的教訓清單PreparetoPresenttotheClass準備到課堂上展示20Minutes20分鐘ErrorProofingExerciseNo.2

IdentifyOpportunitiesforErrors

識別防錯的時機IdentifyOpportunitiesforErrMethodsforIdentifyingPotentialErrors

識別潛在的防錯方法CustomerDemanded-GoodStart消費者的需求-良好的開始InternalQualityResults–Reactive內(nèi)部質(zhì)量成效-反應PastExperience-NotCompletelyReliable以往經(jīng)驗-不完全可靠Customer反饋-TooLate消費者的反饋-太遲SystematicAnalysestoIdentifyPotentialErrors識別潛在的錯誤需進行系統(tǒng)分析PotentialFailureModeandEffectsAnalysis(FMEA)潛在的失效模式及效果分析(FMEA)ProductFMEA產(chǎn)品FMEAProcessFMEA過程FMEAMethodsforIdentifyingPotentPotentialFailureMode

andEffectsAnalyses

PFMEA

潛在的失效模式和

效果分析

Overview總攬PotentialFailureMode

andEfKeyPointsofFMEA

FMEA的關鍵部分FMEAAnalysesPotentialFailuresFMEA分析潛在失效FleasHavetoBeDonebyMulti-functionalTeamsFleas應由多功能組執(zhí)行DesignFMEAShouldBeInitiatedBeforeorattheConceptStage設計FMEA是在開始之前或者概念形成階段ProcessFMEAShouldBeInitiatedBeforeorattheFeasibilityStage,PriortoToolingorEquipmentFinalization過程FMEA是在工裝及設備調(diào)整好開始生產(chǎn)之前或者可研階段FMEAsShouldBeContinuouslyUpdated,AsChangesinProduct&ProcessDesignsTakePlace

應該不斷更新,比如FMEAs中的產(chǎn)品&過程設計FMEAsAreLivingDocumentsFMEAs是活的文件FMEAsAreNeverEndingProcessesFMEAs是永遠都不會結束的工藝KeyPointsofFMEA

FMEA的關鍵部分FMFMEATypeandLevels

FMEA的類型和水平DesignFMEA設計FMEAProcessFMEA過程FMEASubsystem子系統(tǒng)CriticalFeatures關鍵特性Components/Parts零件Subassemblies分裝Workstations工作臺Operations加工操作FMEATypeandLevels

FMEA的類型和水GeneralInformation(1)總說明23456781011912GeneralInformation(1)總說明2345FMEASteps

FMEA

的步驟

DesignFMEA設計FMEAGeneralInformation-DetailsoftheProduct&FMEA信息總說明-產(chǎn)品及FMEA的詳情ItemFunction/Requirement項目的功能/要求EnterAllFunctionsofaProductItem鍵入所有產(chǎn)品的功能PotentialFailureMode潛在的故障模式DescribeHowaProductItemCouldFail描述產(chǎn)品怎樣失效UsePhysicalTerms,NotSymptoms使用專用描述詞語,不是癥狀ProcessFMEA過程FMEAGeneralInformation-DetailsoftheProduct&FMEA信息總說明--產(chǎn)品的詳細資料和FMEAProcessFunction過程功能EnterDescription&PurposeoftheProcess鍵入過程描述和過程功能PotentialFailureMode潛在失效模式DescribeHowProcessCouldFailtoMeetRequirementsofSubsequentOperations描述工藝為什么不能滿足分序要求DescribeNon-conformance描述不一致性FMEASteps

FMEA的步驟

DesignFMFMEASteps

FMEA的步驟DesignFMEA設計FMEAPotentialEffect(s)ofFailure潛在失效效果PerceivedbyCustomer客戶需要Severity(Chart)嚴肅性（圖表）SeriousnessoftheEffectofPotentialFailure潛在失效效果的嚴肅性SeverityRankingReducedOnlybyDesignChange只有設計更改時嚴肅性級別降低Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或功能/基本表象EmployCustomer’sCriteria采用客戶標準ProcessFMEA過程FMEAPotentialEffect(s)ofFailure潛在失效效果PerceivedbyCustomer,IncludingSubsequentOperations客戶需要,包括下述操作Severity(Chart)

嚴肅性(圖表)SeriousnessoftheEffectofPotentialFailure潛在失效效果的嚴肅性Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或功能/基本表象EmployCustomer’sCriteria采用客戶標準FMEASteps

FMEA的步驟DesignFMEASeverityRatingChart

嚴肅性級別表格SeverityRatingChart

嚴肅性級別表格FMEASteps

FMEA步驟DesignFMEA設計FMEAPotentialCause(s)潛在原因ListAlltheCauses(DesignWeaknesses)列出所有原因(設計弱點)Occurrence(Chart)頻率(圖表)LikelihoodoftheFailuretoOccurbytheSpecificCause特殊原因?qū)е率У目赡苄設ccurrenceRankingReducedOnlybyDesignChange僅當設計更改時才考慮降低發(fā)生頻率.DesignControl設計控制Validation/VerificationActivitiesWhichWillAssureAdequacyofDesign驗證/確認活動應確保設計的準確性ProcessFMEA過程FMEAPotentialCause(s)潛在原因IdentifyRootCause,andIdentifyWhatCanBeCorrected確定原因,確定可以采取什么糾正措施Occurrence(Chart)頻率(圖表)ExpectedFrequencyofFailuretoOccurbySpecificCause具體原因?qū)е率Оl(fā)生的頻率Classification(Chart)類別ProcessControlsThatPreventorDetecttheFailure預防或探測缺陷的過程控制FMEASteps

FMEA步驟DesignFMEAOccurrenceRatingChart頻率等級表格

OccurrenceRatingChart頻率等級FMEASteps

FMEA的步驟DesignFMEA設計FMEADetection(Chart)

檢測（圖表）AbilityofaCurrentDesignControltoIdentifyaPotentialCause現(xiàn)行控制設計能力,以識別潛在的原因當前設計的能力ProcessFMEA過程FMEADetection(Chart)檢測（圖表）AssumingFailureHasOccurred,AssessDetectionCapabilityofAlltheProcessControls假設發(fā)生失效,應檢測所有工藝控制的能力RPN(RiskPriorityNo.)RPN(風險優(yōu)先號)ProductofS(Severity),O(Occurrence)&D(Detection)產(chǎn)品的S(嚴重性),O(發(fā)生頻率)&D(檢測)UsedAsaGuidetoHelpRankDesign/ProcessConcerns為進行設計及過程等級等提供向?qū)oThresholdValue無界限值PaySpecialAttentionIfSeverityIsHigh如果嚴重級別高的話,應提高警惕CorrectiveAction,Responsibility,andMonitoringResults實施糾正措施,確定責任人,監(jiān)控結果1112FMEASteps

FMEA的步驟DesignFMEDetectionRatingChart

檢測等級表DetectionRatingChart

檢測等級表SummarizedRatingChart

總結等級表SummarizedRatingChart

總結等級表SummaryofFMEASteps

FMEA步驟匯總FormaMulti-functionalTeam組建多功能小組FailureMode:HowCouldThisPart,SystemorProcessFail?失效模式:該產(chǎn)品,系統(tǒng)或工藝是怎么失效的?EffectoftheFailure:WhatDoestheCustomerExperienceAsaResultoftheFailure?失效影響:作為一種失效模式客戶的經(jīng)驗是怎樣的?CauseofFailure:WhatConditionsCouldBringAbouttheFailureMode?失效原因:關于該失效模式會導致什么情況?Occurrence:ProbabilitytheFailureModeWillOccur發(fā)生:發(fā)生失效模式的可能性Severity:WeighingtheConsequenceoftheFailureMode嚴重性:衡量失效模式的結果Detection:ProbabilitytheFailureModeWillNotBeDetectedBeforeReachingtheCustomer失效:失效模式在到達客戶之前不會被檢測到.RiskPriorityNo.(RPN):ProductofOccurrence,SeverityandDetection,ThatProvidesRelativePriority.風險號(RPN):產(chǎn)品發(fā)生頻率,嚴重性檢測,提供了相對優(yōu)先權.IdentifyActionItems,AssignResponsibility,andFollowThrough確定實施措施:分配責任,跟蹤執(zhí)行SummaryofFMEASteps

FMEA步驟匯EssentialStepsforErrorProofing防錯的基本步驟IdentifyOpportunitiesforErrors(CriticalFactors)PrioritizePotentialErrorsforProofingAbsolutelyMustPreventtheDefectsProvideContainmentandStudyFurtherMayBeTolerated,WithinPredefinedLimitsIdentifyRootCausesoftheErrorsDevelopandEvaluateErrorProofingOptionsSelectand“Design”theErrorProofingSystemImplement-Plan,Install,Document,Train,MonitorPeriodicallyAssessthePerformanceandImproveFMEAAddressesAlltheseErrorProofingStepsFMEA可以定位所有的防錯步驟AndHelpsPlanforThese為此設置計劃EssentialStepsforErrorProoExercise-3

ProcessPFMEA

過程PFMEA練習第三部分IdentifyOneoftheProcessSteps識別一個過程步驟WalkThroughtheStepsofPFMEA實施整個PFMEA步驟FillOuttheFMEAForm填寫FMEA表格DevelopanActionPlan開發(fā)實施計劃Exercise-3

ProcessPFMEA

過ErrorProofingOptions防錯方案ErrorProofingOptions防錯方案ErrorProofingApproaches防錯方法EliminatePotentialDefects:DesignOutthePotentialsforErrors消除潛在缺陷:對潛在錯誤進行設計PreventDefectsFromOccurring:IdentifythePotentialofError,BeforeItOccurs,andPreventIt防止缺陷發(fā)生:識別潛在錯誤:在錯誤發(fā)生前進行預防DetecttheDefect:ErrorHasAlreadyOccurred,DetectandRemovetheDefectiveProduct檢測缺陷:錯誤已經(jīng)發(fā)生,檢測及移除缺陷件LossControl:PotentialforDefectExists,PotentialExistsforNotDetecting,MinimizeDamageFromtheDefect損失控制:存在潛在缺陷,沒有對潛在缺陷進行探測,使缺陷的傷害最小化.AllTheseApproachesOverlap,NoClearBoundaries所有方法交織在一起,沒有清晰界限ErrorProofingApproaches防錯方法EExample-FireProofingaNewBuilding

例如-新建筑的防火防錯Eliminate:UseOnlyNon-combustibleMaterialforConstruction(Steel,Concrete,Etc.)排除：在建筑中要使用不易燃物質(zhì)（鋼鐵，混凝土等）Prevent:DoNotAllow不允許吸煙ElectricalSystemandComponents使用正確的電氣系統(tǒng)和元件預防：Detect:InstallSmokeDetectorsandFireAlarms檢測：安裝煙霧檢測器和火警系統(tǒng)LossControl:InstallSprinklerSystem,FireExtinguishers,FireHoses損失控制：安裝自動噴淋裝置系統(tǒng)，滅火器，滅火水龍帶，防火軟管等Example-FireProofingaNewExample-AccidentProofa

RailwayCrossing

例子：測試鐵道路口的意外事故EliminateAccidents:BuildaBridge排除事故：建造一座橋PreventAccidents:InstallanAutomaticGate,InAdditiontoLightsandAlarms預防意外事故：除了燈和警報裝置,安裝一個自動門DetectandannounceaPassingTrain:InstallLightsandAlarms檢測和進行一個短期培訓：安裝燈和警報裝置培訓LossControl,inCaseofanAccident:InstallaPayPhone??損失控制，有意外事故時：安裝一個付費電話??InManyCases,LossControlIsNOTanOption在很多情況下,損失控制不是實施方案Example-AccidentProofa

RaFirstStepforErrorProofingOptions

防錯的第一個步驟DecidetheLevelofErrorProofingNeeded需要決定防錯的水平Eliminate,If排除，如果SeverityIsHigh嚴重度高PotentialforOccurrenceIsVeryHigh發(fā)生的可能性很大DetectionIsImpossible檢測是不可能的CostofEliminatingisLow排除成本低Prevent,IfDesignIsCompleted,and防止，如果設計完成SeverityIsLow嚴肅性較低RPNIsLowRPM低AttemptDetectioninMostOtherCasesofPotentialforDefects對其他潛在缺陷進行檢測BasedonPriority以優(yōu)先權為基礎FirstStepforErrorProofingOpportunitiesforErrorProofing

防錯的良機消除預防檢測損失控制產(chǎn)品設計工藝/設備設計車間措施其他質(zhì)量保證措施OpportunitiesforErrorProofiErrorProofingDecisionDiagram

防錯決策圖表PotentialError潛在的錯誤DefectFreeProduct無缺陷產(chǎn)品ErrorsEliminated排除錯誤PreventErrorfromOccurring防止錯誤發(fā)生EliminateDuringProduct/ProcessDesign在產(chǎn)品/過程設計中消除錯誤DetecttheDefect發(fā)現(xiàn)缺陷DefectDetected缺陷檢測DefectPrevented缺陷防止DesignLossControlIntheProduct在產(chǎn)品中設計損失控制DefectHasSeriousConsequences缺陷導致嚴重結果NoNoNoNo無Yes有YesYes有YesDevelopLossControlProcedure開發(fā)損失控制程序ErrorProofingDecisionDiagraKeyPointsforElimination

錯誤排除的關鍵點LargestPotentialDuringDesign設計中的巨大潛能EliminatebyDesigningOutActivitiesWithPotentialforErrors對潛在的錯誤設計活動,進行排除CostEffectiveIfAddressedBeforeFinalizingtheDesigns(Product,Process,Equipment)設計定案之前（產(chǎn)品，程序，器材）計算成本效用MostCostEffectiveMethodofAll大多數(shù)成本效用方法SixSigmaQualityCanBeAchievedOnlyWithExtensiveElimination只有完成大范圍消除措施后才可以完成6SigmaMotorolaMandatesAllProcessesforaNewProducttoBeSixSigmaCapable摩托羅拉要求所有產(chǎn)品工藝都可以使用6Sigma.OnceEliminated,NothingElseisRequired一旦消除,就不需要其他的了KeyPointsforElimination

錯誤排ErrorElimination&Symmetry

排除錯誤和對稱L1L2L1L1MakeThemAsymmetric使其不均勻分布MakeThemCompletelySymmetric使其完全均勻分布PartiallySymmetricParts部分均衡件OR或ErrorElimination&Symmetry

排ErrorElimination&Dimensioning

排除防錯和決定錯誤大小WhichisBetter?哪一個最好？AskWhatisImportantandHowItShouldbeMeasured什么是重要，應怎樣測量ErrorElimination&DimensioniToEliminate

ModifyorRedesign?

通過修改或重新設計排除錯誤?SomeDefectscanbeRemovedbyModifications許多缺陷都可以通過修改排除OthersMayNeedRedesign其他許多需要重新設計ToEliminate

ModifyorRedesigKeyPointsforPrevention

預防的關鍵點EliminationIsBestWaytoPrevent排除是最好的預防方法RobustDesign精力充沛的設計DesigntoTolerateUnavoidableVariations對不可避免的變化進行設計EnsuresAcceptableProductsforWiderVariations

確?？梢越邮艿漠a(chǎn)品允許有較大的變化DesignSoThatErrorsCannotBeMade設計,以免會產(chǎn)生錯誤DesignProducts,Processes,Equipment,FixturesThatWillPreventWrongPartsFromBeingUsed(PokaYokeDevices)設計(PokaYoke裝置)產(chǎn)品,工藝,設備,卡具等可以防止錯誤的裝置.Procedures,Training,DocumentationThatHelpPreventErrors防止錯誤的程序,培訓文件等ErrorProofDocumentGeneratingProcesses-ThatWillPreventManyDefectsFromReachingtheCustomer防止錯誤的文件-阻止太多缺陷到達客戶.Drawings,etc.圖紙等ReturnUnacceptableProductBacktothe“Supplier”把不合格件返回供應商.InstitutionalizePreventionMindset結構化預防措施KeyPointsforPrevention

預防的關ConceptsforPrevention

ontheShopFloor車間預防的理念AlwaysProvideAidforCounting為計算提供依據(jù)HelpIndicateSelectionofParts幫助進行零件選擇ColorCoding,LightedIndicators彩色碼,彩燈指示器ProvideOnlyWhatIsNeeded,PreventAccesstoOthers僅提供所需要的,阻止進入其他部分VerifyMachineSettingsThatControlCriticalDimensionsBeforeMachining驗證設備裝置等,可以在加工前控制標準尺寸EmployTPMforEquipmentandDies設備及模具可以實施TPMImplementMechanismsThatHelptheOperators實施操作者易使用的機械裝置BarCoding,CheckLists,GraphicWorkInstructions條碼,檢驗列表,圖表化的操作說明InvolvetheOperators包括操作者CarefullyDispositionRejectedParts仔細處理不合格件AvoidRepetitive,Monotonous,HazardousTasks避免重復，單調(diào)，危險的任務Standardize標準化ConceptsforPrevention

onthDesignedtoPreventDefects

預防缺點的設計DesignedtoPreventDefects

預防SensorstoDifferentiateIdenticalParts

區(qū)別可互換零件的傳感器L1L2AlmostIdenticalParts幾乎是可互換零件CoordinatedLightSensorsDifferentiatetoPreventErrors用燈傳感器來區(qū)分預防錯誤SensorstoDifferentiateIdentDetectPresenceorAbsencetoPreventDefects

使用存在或不存在缺陷的方法預防缺陷Verify

PresenceofScrewstoPreventAssembliesWithoutScrews確定螺絲的存在來預防裝配忘記螺絲DetectSplicetoHelpDiscardtheSection探測接口幫助廢棄某部分Verify

LiquidLeveltoPreventShippingUnfilledBottle確認液體水平,來預防未裝滿瓶子運走DetectPresenceorAbsencetoVariousTypesofCounters

toPreventDefects

各種型號的計算器來防止缺陷2134BreakingtheLightCurtain斷掉燈的線路LightReflectingSensors燈光反映感應器InductanceSensors自感應器VariousTypesofCounters

toKeyPointsforDetection探測的關鍵點PokaYokeDevicesCanAddressMostoftheManufacturingDefectsPokaYoke裝置可以探測大多數(shù)生產(chǎn)缺陷的位置DetectionTakesCareofWhatWasNotPreventedUpstream,orintheCurrentProcess可以探測到以前沒有預防住的點,或現(xiàn)場工藝中的錯誤DetectionShouldTarget“Direct”Parameter,Examples:探測需定位正確的參數(shù),例如:MeasurePressureUndertheNut,NottheTorque測量螺母下面的壓力,而不是扭矩下面的壓力MeasureWeldStrength,NotWeldingCurrent測量焊接件的強度,而不是焊接件的電流DetectionMustBeClosetotheProcess探測必須接近工藝RightBeforeforIncomingParts進件以前正確RightAfterforCompletedActivity完成活動以后正確DetectionShouldRejectUnacceptableParts&ProvideImmediatefeedback(PokaYokeDevices)探測應拒收不合格件&立即提供反饋(PokaYoke裝置)DetectionShouldBeReliable,CertifiableandMonitored探測須是可靠的,有保證的,可以監(jiān)控的.KeyPointsforDetection探測的關鍵點MeasureDimensions(Go,NoGo)

toDetectDefects

測量尺寸(通止規(guī))來探測缺陷MeasureSheetThickness測量鋼板厚度MeasureDiameter測量直徑MeasureSheetWidth測量鋼板寬度MeasureDimensions(Go,NoGo)DetectDifferentFeatures

探測不同的特性DetectPickupofaSheet探測鋼板位置DetectPresenceofFeatures探測特性的存在性DetectColorAccuracy探測顏色精確性DetectDifferentFeatures

探測不同DetectionUsingContact

使用接觸探測RememberThisPart?是否記得這個零件?WhattoDoIfItCannotberedesigned?如果不能重新設計怎么做FixtureDesignedtoDetectIncorrectOrientation設計卡具檢測位置正確性DetectionUsingContact

使用接觸探測DetectingDimensionUsingContact用接觸法測定尺寸Accept可接受件Reject廢棄件GoodPart合格件BadPart不合格件DetectingDimensionUsingContKeyPointsforLossControl損失控制的關鍵點Design,IntheProduct,AvoidanceofCatastrophicResults在產(chǎn)品設計中避免大的損失SeveralBackupSystemsinAircraft,EjectionSeats,Parachute航行器,排除座,降落傘的備份系統(tǒng)Airbag安全氣袋LimitedClinicalTrialsonHumansofNewDrugs新藥物對人進行臨床實驗FinalFunctionalTests,BeforeShipping運輸前的最后功能實驗NothingDetectedonIndividualParts不對單獨件進行檢驗ScheduledMaintenanceChecksofMissionCriticalItems對于關鍵項目任務提供定期維修ShouldBetheLastResort對關鍵物品進行定期維修檢驗,應該有檢驗報告DriversDoGetinAccidents,SaveThemWithAirbags司機遇到交通事故時,安全氣囊可以對他們進行保護NOTDesignUnsafeCars不要設計不安全的汽車EarlyCommunication,RecallsAreExtremelyImportantforLossControl早期交流,招回對損失控制是非常重要的KeyPointsforLossControl損失控TraditionalQualityControl

VersusErrorProofing

傳統(tǒng)的質(zhì)量控制與防錯進行比較Op1Op2Op3Op4Test/Inspect檢驗/檢測Scrap廢品Accept接受Op1Op2Op3Op4Verify確定確認Verify確定確認Verify確定確認Feedback反饋Feedback反饋Feedback反饋Traditional,CompleteProduct&TestorInspect傳統(tǒng),完成產(chǎn)品實驗及檢驗ErrorProofing,Verify

AfterEveryOperation&反饋每一序后以及反饋后進行防錯確認DetectionVersusPrevention探測與預防的比較TraditionalQualityControl

VTraditionalQualityControl

VersusErrorProofing

傳統(tǒng)的質(zhì)量控制與防錯進行比較TraditionalQUALITYCONTROL傳統(tǒng)質(zhì)量控制InspectorTestFunctionalitytoDetectDefectiveproduct(FinalProductDefect)功能檢測及實驗來探測缺陷產(chǎn)品(最后產(chǎn)品缺陷)TheTestProduces“Accept”“Reject”Judgement通過實驗選出合格件與不合格件TestorInspectAfterSeveralOperations幾序以后進行實驗與檢測DifficulttoPinpointCauseoftheDefect精確找出缺陷原因很困難NoDirectfeedback

totheOffendingOperation對于不穩(wěn)定序沒有直接反饋LongDelayBetweenError&DiscoveryofDefect錯誤產(chǎn)生與發(fā)現(xiàn)缺陷之間拖延太長ErrorProofing防錯Verify

SpecificCharacteri-stic&PreventErrororDetectInter-processDefect確定具體的防錯以及工藝缺陷預防Verification“Catches”DefectiveComponent確認捕捉缺陷件VerificationIsImmediate立即確認RelationofDefect&ErrorIsAlreadyKnown缺陷與錯誤之間的關系已知道FeedbackIsImmediate立即反饋NoDelayinDefectDiscovery不能拖延缺陷件的發(fā)現(xiàn)TraditionalQualityControl

VTraditionalQualityControl

VersusErrorProofing-Results

傳統(tǒng)的質(zhì)量控制與防錯進行比較-結果Op1Op2Op3Op4Test/In