1、MISTAKE-PROOFING防誤措施,ACEElements,QCPC,RootCause/CorrectiveAction,Passport,MistakeProofing,MarketFeedbackAnalysis,6S,QualityClinicActivity,TPM,ACE內(nèi)容,質(zhì)量診斷程序圖表,根本原因修正行動,設(shè)計開發(fā)通行證,防誤措施,市場反饋分析,6S,質(zhì)量診斷行動,全面生產(chǎn)性維護,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內(nèi)容,開發(fā)新產(chǎn)品、程序和系統(tǒng)設(shè)計開發(fā)通行證-檢查/批準新設(shè)計的系統(tǒng)方法,標準方法程序管理識別并展示

4、重要商業(yè)程序的方法標準化作業(yè)-可重復的有效程序,質(zhì)量改進方法質(zhì)量診斷程序圖表-識別問題和低效率（返工）的簡單工具市場反饋分析-展示組件是怎樣工作的數(shù)據(jù)摘要根本原因-發(fā)現(xiàn)問題的真正來源的方法,標準環(huán)境新6S-工作場地組織和直觀控制全面生產(chǎn)性維護-不斷地改善設(shè)備的有效性和可用性,防誤措施-確保任務總能正確完成的設(shè)備的措施,Increaseprofitabilitybyeliminatinginadvertentmistakes消除無謂的錯誤可增加利潤率Increaseproductivitybyreducingwastedtime減少浪費的時間可提高生產(chǎn)力Improvecustomersatisf

5、actionandqualitybyeliminatingescapes消除逃脫可提高客戶滿意度和質(zhì)量Increasereliabilitybycontinuouslyimprovingproducts,servicesorprocesses不斷改進產(chǎn)品、服務或程序可提高信譽,BenefitsofMistake-Proofing防誤措施的好處,Theyarenotthesamething!MistakesCauseDefects.他們是不同的！錯誤導致過失,Mistakesvs.Defects錯誤vs過失,Mistake錯誤,Defect過失,Pumpingdieselfuelintoyour

6、gastank.將柴油加入汽油箱,Runningaredlight.撞紅燈,Forgettingtounplugyouriron.忘記拔掉電熨斗的插頭,Placingthe“original”inyourcopierfeeder“facedown”.將原件放進了復印機的進紙?zhí)幉⒄鏇_下,or,Misunderstandingrequirements誤解了要求Skippingaprocesssteportasks漏掉了一個工作步驟Performingprocessstepsincorrectlyorinthewrongorder未正確地或以錯誤地順序執(zhí)行程序步驟Contamination污染,M

7、ostCommonMistakes最常見的錯誤,Leavingoutapartorapieceofinformation漏掉了一個零件或一條信息Adjustmentandmeasurementmistakes調(diào)節(jié)和測量錯誤Timingmistakes定時錯誤Usingthewrongpart,toolorinformation使用了錯誤的零件、工具或信息,Mistake-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalwaysdonecorrectly.防誤措施是指運用智慧和獨創(chuàng)性發(fā)展出一個能確保

8、任務總是能正確完成的設(shè)備的方法。,Mistake-Proofing防誤措施,Itremovesuncertaintyfromthesituationswhereerrorsaremostlikelytooccur,suchas:它去除了最可能發(fā)生錯誤的情形中的不確定性，如：Repetitivetasks重復性的任務Complexinstructions復雜的說明書Calculations/Adjustments計算/調(diào)節(jié)Look-alikeparts相似的零件,WhydowedoMistakeProofing?為什么我們要采用防誤措施？,Topreventturnbacksandcustome

9、rescapesfromrecurring,sincethecosttofixaproblemincreasesrapidlythelateritisfound:為防止缺陷和客戶逃脫情況再次發(fā)生，因為問題發(fā)現(xiàn)得越晚所花的費用就會迅速增加：,Ifadefectoccurshere如果在這兒發(fā)生過失,anditsfoundhere,并在這兒被發(fā)現(xiàn)，itcosts:就要花費：,Rework,repair,scrapandescapescostUTC$148millionperyear.Warrantyexpensescostusanother$600millionperyear.Thecostofl

10、ostcustomerloyaltyduetoescapesisimmeasurable.返工、修理、廢棄和逃脫每年要花掉UTC1.48億。保修費用每年花掉我們另外6億。由于逃脫而喪失了客戶的信任的損失則不可計算。,Mistake-Proof防誤措施theDesign設(shè)計Redesigntheproduct重新設(shè)計產(chǎn)品Eliminatethemistakecondition消除犯錯誤的條件Redesignforsymmetryorasymmetry重新進行對稱或不對稱設(shè)計Changethematerials改變材料Changecomponenttype,characteristicsorsup

11、plier改變組件的類型、特征或供應商,2ApproachestoMistakeProofing預防錯誤的2個途徑,Mistake-Proof防誤措施theProcess加工Changeoraddtooling改變或增添工具Changeprocesssteps改變加工步驟Adduseofchecklists,templatesorgages增加使用清單、模板或測量儀Implementcontrolcharts執(zhí)行控制圖表,ProcessDescription:Makingapotofcoffee程序描述：泡一壺咖啡,ExampleofMistake-ProofingtheDesign防誤措施范

12、例設(shè)計,BeforeImprovement:改進前：Waterneededtobemeasuredforeachpotofcoffeeoftenresultingincoffeethatwastooweakortoostrong泡前每壺咖啡的水量都要測量常常導致咖啡過淡或過濃。,ProcessDescription:Makingapotofcoffee程序描述：泡一壺咖啡,ExampleofMistake-ProofingtheDesign防誤措施范例設(shè)計,AfterImprovement:改進后：Coffeemakerwasredesignedtomeasureandaddtheprecis

13、eamountofwaterfromawaterbottle重新設(shè)計咖啡機以使每次從水瓶中加入的水的量都一樣多,ProcessDescription:Alabelispastedintoarecessinamoldedchassis程序描述：將標簽貼在底盤的凹槽內(nèi),ExampleofMistake-ProofingtheDesign防誤措施范例設(shè)計,BeforeImprovement:改進前：Therecessandthelabelwerebothrectangular.Thelabelcouldbegluedinupside-down.凹槽和標簽都是長方形。標簽可能會貼反。,AfterImp

14、rovement:改進后：Anotchwasmadeinthecornerofthelabel,andintherecessofthechassis.Incorrectmountingiscompletelyeliminated.在標簽和凹槽的一角做一個切口。就能完全防止錯誤發(fā)生。,ExampleofMistake-ProofingtheDesign防誤措施范例設(shè)計,ProcessDescription:Installslidesintoaslideprojector程序描述：將幻燈片裝入幻燈機中,BeforeImprovement:改進前：Aresomeslidesupsidedown?有一

15、些幻燈片裝反了嗎？,AfterImprovement:改進后：Topedgeofeachslidemarkedwithareddot.每張幻燈片的上邊都有一紅點。,ExampleofMistake-ProofingtheDesign防誤措施范例設(shè)計,ProcessDescription:Torquinganumberofboltsrecesseddeepinacavity.程序描述：將大量螺栓擰進空腔深處的凹槽內(nèi),BeforeImprovement:改進前：Thesocketextensionrequiredtoreachtheboltscausednicksandscratchesinthe

16、paintedsurfacesthatitcontactedduringassembly.在操作的過程中，用來擰螺栓的擰桿柄會對油漆表面造成刮傷。,AfterImprovement:改進后：Arubberhosewasinstalledoverthesocketextensionandwasspecifiedontheworkinstructions.一個橡皮管被裝在擰桿柄上并在工作說明書上有詳細說明。,Mistake-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalwaysdonecorrect

17、ly.防誤措施是指運用智慧和獨創(chuàng)性發(fā)展出一個能確保任務總是能正確完成的設(shè)備的方法。,Mistake-ProofingisntWords!防誤措施不是文字！,Word“Solution”文字“解決方法”,Problem:The“OneDay“employeebadgeformasksforbadge#andclock#.Employeesoftenwritetheirclock#inthebadge#spot.問題：“一日”雇員的證件表格要求填寫證件號和鐘點號。雇員常將鐘點號填在證件號的位置。,Badge#證件號,Clock#鐘點號,(filledoutbyEmergencyServices)（

18、由緊急服務部填寫）,(filledoutbyemployee)（由雇員填寫）,Guidepinsorinterferencepins向?qū)D釘或干涉圖釘Templates模板Partkitsusingshadowboxing使用能防止錯誤的零件包Limitswitches限制閥,MostCommonTypesofMistake-ProofDevices最常見的防誤設(shè)備,Counters計算器Alarms鬧鐘Weightsandmeasures稱重秤和測量儀Checklists清單Controlcharts控制圖表,Mistake-ProofingProcessChanges防誤碼程序的改變,Im

19、provetheprocess!改進程序！Simplify簡單化Reducesteps,parts,forms,dataonforms,numberofprocesssteps,etc.減少步驟、零件、表格、表格上的數(shù)據(jù)、加工步驟的數(shù)量等。Consolidate/Co-Locate鞏固/共用Bringoperationsclosertogether,reducework-in-process(WIP)使操作變得更緊湊，減少過程工作（WIP）Standardize標準化Maketheprocessvisual使程序可見Moveresponsibilityandauthoritydowninthe

20、organization將責任和權(quán)利下放給組織,Try-Storming(vs.Brainstorming)嘗試風暴（對頭腦風暴）Involvetherightpeople讓合適的人參與Walktheprocessandgetthefacts檢驗程序并獲得事實Dontjustsitandthinkaboutsolutions.TRYTHEM!不要只是坐在那兒想解決問題的方法去嘗試！,CreatingMistakeProofing創(chuàng)建防誤措施,The“NastyTest”(vs.the“Solution”)“惡心的試驗”（對“解決方法”）Whenyouthinkyouvegotthebestso

21、lutionTRYTOMAKEITFAIL!當你認為你已找到最佳解決方法時試著去讓它失敗Involveallusers讓所有使用者參與Mistake-proofdevicesmustbe100%effectiveatdealingwithaparticularmistake在處理特殊錯誤時防誤設(shè)備必須100%有效Ifnot,theywillbeignored如果不能，就應放棄Ensurethemistake-proofdoesntcreateanotherproblem確保防誤措施不會引起其它問題,TestMistakeProofingwiththe“NastyTest”用“惡心的試驗”來驗證

22、防誤措施,Formally,aspartoftheQCPC/MFAProcess形式上的，作為QCPC/MFA程序中一部分,WhendoyoudoMistake-Proofing何時采取防誤措施,2)Real-time,wheneveryounoticeamistaeoccurringorthepotentialforamistake實時的，無論何時你發(fā)現(xiàn)一個錯誤或有出錯的可能性,Thereare3LevelsofMistake-Proofingbasedoneffectivenessandspeed:防誤措施有三個基于有效性和速度的等級：LevelIII:Detection等級三：發(fā)現(xiàn)Lev

23、elII:Alert等級二：警告LevelI:Prevention等級一：防止,ThreeLevelsofMistake-Proofing防誤措施的三個等級,LevelIII,Detect:AllowsyoutodetectyourMistakeafterithasoccurred.(1point)等級三，發(fā)現(xiàn)：在已經(jīng)發(fā)生之后發(fā)現(xiàn)錯誤Checklists清單Computerbeeps電腦提醒ManuallyactivatedSpellCheck手工拼寫檢查LevelII,Alert:AlertsyouastheMistakeishappening.(2points)等級二，警告：當錯誤正在發(fā)生時提醒你Sensors,alarms,controlcharts傳感器、鬧鐘、控制圖表Counters計算器AutomaticSpellCheck自動拼寫檢查LevelI,Prevent:PreventsyoufrommakingtheMistake.(3points)等級三，防止：防止你犯錯誤Eliminatingthemistakecondition(changingthedesign)消除犯錯條件Automation自動控制Spelling“Auto-corrector”拼寫“自動更正器”,ThreeLevelsofMistake-Proofing防誤措施的三個