精益生產(chǎn)防錯

ErrorProofing

防錯Topics-ErrorProofingTraining

Topics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轉入下一級ABenchmarkWithinEaton伊頓內部標準Summary概要ObjectivesoftheTraining

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WhatAreYourExpectations?

你們的期望是什么？WhatandWhyofErrorProofing

什么是防錯以及為什么要防錯Definition

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(內部防錯和外部防錯)ErrorProofingbyOtherNames

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DefectsinProductsAretheImperfections(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!!WhyAreErrorsMade為什么會會導致錯錯誤AnyProductIsaResultofNumerousDecisionsMadeandActionsTakenbyHumanBeings,During:任何產(chǎn)品品都可以以在下述述一系列列人為行行為中產(chǎn)產(chǎn)生錯誤誤：ProductDesign產(chǎn)品設計計ProcessDesign過程設計計EquipmentDesign設備設計計ComponentFabricationProcesses零件加工工過程ProductAssemblyProcesses產(chǎn)品裝配配過程InspectionProcesses檢驗過程程PaperworkGeneration程序行程程過程Etc.等等AndHumanBeingsareFallibleorImperfect人是容易犯錯錯或不完美的的SOMEExamplesofDefects屬于缺陷的一一些例子WrongorInappropriateMaterial錯誤或不適合合的材料WrongorNon-functioningComponents錯誤或者沒有有功能的零件件WrongDimensionsorTolerances尺寸或公差錯錯誤MissingComponents零件漏裝ForeignMatters,Contamination雜質物質,污穢物DamagedProductorComponents受損產(chǎn)品或零零件WrongPaperwork,orWrongProductShipped程序錯誤或者者運輸了錯誤誤的產(chǎn)品Non-functioningorMalfunctioningProduct沒有功能的的產(chǎn)品或者者是故障產(chǎn)產(chǎn)品WrongShipping,orWrongBilling運輸錯誤或或者是填單單錯誤SOMEExamplesofCausesofDefects導致缺陷的的一些例子子PoorDesignDecisions設計比較乏乏味OmittedorWrongProcessing過程疏忽或或過程錯誤誤Missing/ExtraPartsorWrongParts漏裝/多裝裝了錯誤的的零件OmittedorWrongAdjustment/Testing遺漏漏調調整整/測測試試或或調調整整/測測試試過過程程錯錯誤誤WrongEquipmentSetuporLossofSetup設備設設置錯錯誤或或沒有有進行行設備備設置置WrongMaterial,ComponentsorAssemblies材料，，零件件或者者裝配配錯誤誤WrongCommunication,Instructions,Procedures,orMethods錯誤的的信息息，指指令，，程序序，或或者方方法Inexperience,LackofTraining,WrongTraining,LackofRetraining缺乏經(jīng)經(jīng)驗，，缺乏乏培訓訓，培培訓錯錯誤，，缺少少再培培訓SOMEExamplesofResultsofDefects缺陷導致致的結果果示例MalfunctionorNon-functioningProduct有故障或或者缺乏乏機能的的產(chǎn)品Inconvenience,Discomfort,Injury,Death麻煩，不不便，傷傷害，死死亡Delays,Cancellations延期，取取消FinancialLosses財政損失失LossofUseorProductivity效用或者者生產(chǎn)力力的缺乏乏DamagetoCustomer’’sProperty損害客戶戶的利益益LiabilitiesandLawSuites負債和法法律問題題LossofReputationandBusiness名譽和業(yè)業(yè)務受損損SOMECausesofHumanErrors導致人們們犯錯誤誤的一些些原因Forgetfulness,LossofConcentration,LackofAttentionorDivertedAttention健忘，不不集中，，缺乏注注意力或或者轉移移注意力力MisunderstandingorLackofUnderstanding誤會或者者缺乏理理解LackoforImproperExperience/Training缺乏經(jīng)驗驗/培訓訓或者不不正確的的經(jīng)驗/培訓LackofStandardization缺乏標準準IntentionalorWillfulError有意圖的的或者惡惡意的錯錯誤WrongorDelayedDecision決定錯誤誤或拖延延LimitedorLackofSensoryCapability(e.g.,Smell,Color,Touch)有限的或或者沒有有感官能能力（例例如，嗅嗅覺，色色彩，觸觸覺）LackofApplicationofCommonSense缺乏運用用常識判判斷的能能力ErrorProofinginaFewWords預防錯誤誤的一些些方法“…occurrenceofdefectwastheresultofsomeconditionoraction,andthatitwouldbepossibletoeliminatedefectsentirelybypursuingthecause.Thecausesofdefectslieinworkererrors,anddefectsaretheresultsofneglectingthoseerrors.Itfollowsthatmistakeswillnotturnintodefectsifworkererrorsarediscoveredandeliminatedbeforehand.”缺陷的產(chǎn)產(chǎn)生是一一些環(huán)境境或者行行為導致致的結果果，但是是完全有有可能通通過查找找原因排排除缺陷陷。缺陷陷原因在在于工人人，缺陷陷是因為為工人忽忽視錯誤誤而產(chǎn)生生的。如如果工人人能及時時的發(fā)現(xiàn)現(xiàn)錯誤并并且消除除錯誤，，就不會會導致缺缺陷的產(chǎn)產(chǎn)生。ShigeoShingoWhyErrorProof?為什么防錯錯？99.9%ErrorFreeCouldResultin99.9%沒有錯誤誤導致什么么結果2,000,000DocumentsLostbyIRSIRS缺少2，000，000檔案案16,000PiecesofMailLostEveryDay每天丟失16，000郵件22,000WronglyDebited/CreditedChecksPerHour每個小時都都會發(fā)生22，000寫錯借借方和貸方方的支票1,314WronglyConnectedPhoneCallsPerMinute每個小時都都會發(fā)生1，314起電話占占線20,000IncorrectDrugPrescriptionsPerYear每個小時都都會發(fā)生20，000起用錯錯藥物的情情況12NewbornBabiesGiventoWrongParents12個小孩孩被父母抱抱錯2UnsafeLandingsEveryDayatO’’HareAirport每天都會有有2起飛機機不安全著著陸32,000MissedHeartbeatsPerPersonEachYear每年每個人人都會有32，000Is99.9%GoodEnough???99.9%夠不夠好???TheErrorsThatBecameHeadlines錯誤變成頭頭條TitanicSinking泰坦尼克號號的沉沒ChallengerBoosterRocketSealFailure挑戰(zhàn)者號火火箭發(fā)射失失敗MarsLandingModuleCrash火星升空失失敗墜毀HubbellTelescopeReflectorErrorHubbell望遠鏡反射射誤差ExxonValdezOilSpillExxonValdez石油泄露ChernobylNuclearPowerPlantMeltdownChernobylNuclearPower設備報廢ReleaseofMethylIsocyanate(MIC)FromUnionCarbidePlantinBhopal,India甲基異丙酮酮從Bhopal,India,MIC碳化物廠房房泄露ThreeMileIslandNuclearPlant三英里小島島的核廠房房FirestoneTiresonFordExplorer福特車上的的耐火石探探測器ErrorProofingandLean防錯及精益益生產(chǎn)LeanInsistsonOnePieceFlow精益生產(chǎn)強強調單件流流IfThatOnePieceIsDefective,FlowIsDisrupte如果單件流流有缺陷,流向就會會被打斷LeanInsistsonLimitedInventory精益生產(chǎn)強強調有限庫庫存IfThatInventoryIsDefective,theLinesCanSto如果庫存有有缺陷,線線路就會停停止LeanMeansEliminatingWaste精益是指消消除浪費DefectsandCorrectiveActionsAreWast缺陷以及糾糾正措施是是針對浪費費LeanRequiresThatEquipmentIsReadyWhenNeededandFunctionsWellAsLongAsNecessary精益生產(chǎn)要要求當需要要設備時,設備馬上上可以用,且功能完完好ErrorProofingtheTools,Fixtures,Setups,MethodsandDocumentsEnsuresEquipmentEffectiveness刀具,卡具具,啟動,方法以及及文件等防防錯以確保保設備的有有效性ErrorProofingExamplesinEverydayLife在每天生活活中防錯的的一些例子子Home家里AutomaticShutoffIrons全自動熨斗GroundFaultCircuitBreakersforBathroomorOutdoorElectricCircuits浴室或室外外電氣線路路的接地保保護PilotlessGasRangesandHotWaterHeaters油量表以及及熱水器Child-ProofCapsonMedicineBottles藥瓶上保護小孩安安全的瓶蓋蓋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處處理軟件中中進行拼寫檢檢查Verifying“Doyouwanttodelete?”WhenPressthe“Delete”ButtononYourComputer當按刪除按鈕鈕時電腦會會詢問你““要刪除嗎嗎”?Factory工廠DualPalmButtonsandOtherGuardsonMachinery設備上使用兩個按按扭及其他他保護裝置置BarCoding條碼Lock-Out/Tag-Out鎖緊/打開標簽ErrorProofingExerciseNo.1防錯練習的的第一部分分FormTeamsofTwo兩個一組ListAsManyExamplesofErrorProofingAsYouCan,FromEverydayLife從你每天的的生活中,列出你能作作到的關于于防錯的許許多例子10Minutes10分鐘ApplicationofErrorProofing防錯的應用用EssentialStepsforErrorProofing防錯的基本本步驟IdentifyOpportunitiesforErrors(CriticalFactors)識別防錯的的時機(關鍵因素)PrioritizePotentialErrorsforErrorProofing對潛在的錯錯誤加以，，區(qū)分進行行防錯AbsolutelyMustPreventtheDefects必須完全的的防止錯誤誤ProvideContainmentandStudyFurther預防錯誤和和深入研究究MayBeTolerated,WithinPredefinedLimits在計劃的范范圍內進行行防錯IdentifyRootCausesoftheErrors識別錯誤根根源DevelopandEvaluateErrorProofingOptions開發(fā)和評估估防錯方案案Selectand“Design”theErrorProofingSystem選擇和設計計防錯系統(tǒng)統(tǒng)Implement-Plan,Install,Document,Train,Monitor實施防錯－－設計反錯錯，安裝防防錯,編制防錯文文件,培訓,監(jiān)控PeriodicallyAssessthePerformanceandImprove對防錯情況況進行定期期評審及改改進ManufacturingProcesses制造過程ProductQuality產(chǎn)品質量ProcessDesign過程設計ProductDesign產(chǎn)品設計WhatistheRightTimetoErrorProof??正確的防錯錯時間是什什么時間?100:110:11:1AsEarlyAsPossible及早發(fā)現(xiàn)WhyErrorProofEarlyDuringNewProductDevelopment為什么在新新產(chǎn)品開發(fā)發(fā)期間防錯錯Costof““Fixing”theDefects““修理”缺陷陷的成本ConceptDevelopment觀念開發(fā)PreliminaryDesign初步設計DetailedProductDesign詳細的產(chǎn)品品設計CustomerSupport客戶支持Industrialization產(chǎn)業(yè)化Production生產(chǎn)ProcessDesign過程設計Costof““Fixing”設備的花費費MultipliesWithLifeCycleStages整個過程當當中的多項項防錯StagesofProductLifeCycle產(chǎn)品品生生命命周周期期中中各各個個階階段段WhyErrorProofEarlyDuringProcessing在處處理理期期間間為為什什么么要要盡盡早早防防錯錯Costof““Fixing””theDefects設備備成成本本失失效效IncomingParts外協(xié)協(xié)件件AfterCompletingtheProcess過程程完完成成之之后后AttheEndoftheLine產(chǎn)品最最終離離開生生產(chǎn)線線AfterDeliverytoCustomer交付給客戶戶之后FinalTest最后檢驗Costof““Fixing”IncreasesWithProcessSteps隨著程序步步驟增長修修復錯誤成成本增長StepsofProductProcessing產(chǎn)品處理的的步驟Reject&Return廢棄件NoDelay沒有拖延Reject&Scrap廢棄件&廢廢品MinorDelay稍微拖延Reject&Scrap/Rework廢棄件&廢廢品/返工工RescheduleSomeDelay進度稍有拖拖延SignificantRework/ScrapAddtotheProductionScheduleDelayedDeliveries重要的返工工/廢品影影響生產(chǎn)進進度及產(chǎn)品品交付WarrantyCostsAdministrativeCostsLiabilitiesReputationMarketShareLoss擔保成本及及管理成本本增加,導導致市場份份額損失ErrorProofingExerciseNo.2防錯訓練的的第二部分分FormTeamsofTwo兩個一組DiscussandAgreeonOneExampleofProductDesignorManufacturingProcesstoAnalyze討論一個個產(chǎn)品設設計或制制造工藝藝的例子子,并進進行分析析Identify鑒別ErrorProofingImplemented防錯實施施EstimateCost/QualityImpact消除成本本/質量量影響OR或者ErrorProofingOpportunitiesMissed喪失防錯錯良機EstimatetheCost/QualityImpact消除成本本/質量量影響ListLessonsLearned學到的教教訓清單單PreparetoPresenttotheClass準備到課課堂上展展示20Minutes20分鐘IdentifyOpportunitiesforErrors識別防錯錯的時機機MethodsforIdentifyingPotentialErrors識別潛在在的防錯錯方法CustomerDemanded-GoodStart消費者的的需求-良好的的開始InternalQualityResults––Reactive內部質量量成效-反應PastExperience-NotCompletelyReliable以往經(jīng)驗驗-不完完全可靠靠Customer反饋-TooLate消費者的的反饋-太遲SystematicAnalysestoIdentifyPotentialErrors識別潛在在的錯誤誤需進行行系統(tǒng)分分析PotentialFailureModeandEffectsAnalysis(FMEA)潛在的失失效模式式及效果果分析(FMEA)ProductFMEA產(chǎn)品FMEAProcessFMEA過程FMEAPotentialFailureModeandEffectsAnalysesPFMEA潛在的失失效模式式和效效果分分析Overview總攬KeyPointsofFMEAFMEA的關鍵部部分FMEAAnalysesPotentialFailuresFMEA分析潛在在失效FleasHavetoBeDonebyMulti-functionalTeamsFleas應由多功功能組執(zhí)執(zhí)行DesignFMEAShouldBeInitiatedBeforeorattheConceptStage設計FMEA是在開始始之前或或者概念念形成階階段ProcessFMEAShouldBeInitiatedBeforeorattheFeasibilityStage,PriortoToolingorEquipmentFinalization過程FMEA是在工裝裝及設備備調整好好開始生生產(chǎn)之前前或者可可研階段段FMEAsShouldBeContinuouslyUpdated,AsChangesinProduct&ProcessDesignsTakePlace應該不斷更更新,比如如FMEAs中的產(chǎn)品&過程設計計FMEAsAreLivingDocumentsFMEAs是活的文件件FMEAsAreNeverEndingProcessesFMEAs是永遠都不不會結束的的工藝FMEATypeandLevelsFMEA的類型和水水平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GeneralInformation(1)總說明23456781011912FMEAStepsFMEA的步驟DesignFMEA設計FMEAGeneralInformation-DetailsoftheProduct&FMEA信息息總總說說明明-產(chǎn)產(chǎn)品品及及FMEA的詳詳情情ItemFunction/Requirement項目目的的功功能能/要要求求EnterAllFunctionsofaProductItem鍵入入所所有有產(chǎn)產(chǎn)品品的的功功能能PotentialFailureMode潛在的故故障模式式DescribeHowaProductItemCouldFail描述產(chǎn)品品怎樣失失效UsePhysicalTerms,NotSymptoms使用專用用描述詞詞語,不不是癥狀狀ProcessFMEA過程FMEAGeneralInformation-DetailsoftheProduct&FMEA信息總說說明--產(chǎn)品品的詳細細資料和和FMEAProcessFunction過程功能能EnterDescription&PurposeoftheProcess鍵入過程程描述和和過程功功能PotentialFailureMode潛在失效效模式DescribeHowProcessCouldFailtoMeetRequirementsofSubsequentOperations描述工藝藝為什么么不能滿滿足分序序要求DescribeNon-conformance描述不一一致性FMEAStepsFMEA的步驟驟DesignFMEA設計FMEAPotentialEffect(s)ofFailure潛在失失效效效果PerceivedbyCustomer客戶需需要Severity(Chart)嚴肅性（圖表表）SeriousnessoftheEffectofPotentialFailure潛在失效效果果的嚴肅性SeverityRankingReducedOnlybyDesignChange只有設計更改改時嚴肅性級級別降低Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或或功能/基本本表象EmployCustomer’’sCriteria采用客戶標準準ProcessFMEA過程FMEAPotentialEffect(s)ofFailure潛在失效效果果PerceivedbyCustomer,IncludingSubsequentOperations客戶需要,包包括下述操作作Severity(Chart)嚴肅性(圖表表)SeriousnessoftheEffectofPotentialFailure潛在失效效果果的嚴肅性Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或或功能/基本本表象EmployCustomer’’sCriteria采用客戶標準準SeverityRatingChart嚴肅性級別表表格FMEAStepsFMEA步驟DesignFMEA設計FMEAPotentialCause(s)潛在原因ListAlltheCauses(DesignWeaknesses)列出所有原因因(設計弱點)Occurrence(Chart)頻率(圖表)LikelihoodoftheFailuretoOccurbytheSpecificCause特殊原因導致致失效的可能能性OccurrenceRankingReducedOnlybyDesignChange僅當設計更改改時才考慮降降低發(fā)生頻率率.DesignControl設計控制Validation/VerificationActivitiesWhichWillAssureAdequacyofDesign驗證/確認活動應確確保設計的準準確性ProcessFMEA過程FMEAPotentialCause(s)潛在原因IdentifyRootCause,andIdentifyWhatCanBeCorrected確定原因,確定可以采取取什么糾正措措施Occurrence(Chart)頻率(圖表)ExpectedFrequencyofFailuretoOccurbySpecificCause具體原因導致致失效發(fā)生的的頻率Classification(Chart)類別ProcessControlsThatPreventorDetecttheFailure預防或探測缺缺陷的過程控控制OccurrenceRatingChart頻率等級表格格FMEAStepsFMEA的步驟DesignFMEA設計FMEADetection(Chart)檢測（圖表））AbilityofaCurrentDesignControltoIdentifyaPotentialCause現(xiàn)行控制設計計能力,以識識別潛在的原原因當前設計的能能力ProcessFMEA過程FMEADetection(Chart)檢測（圖表））AssumingFailureHasOccurred,AssessDetectionCapabilityofAlltheProcessControls假設發(fā)生失效效,應檢測所所有工藝控制制的能力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為進行設計及及過程等級等等提供向導NoThresholdValue無界限值PaySpecialAttentionIfSeverityIsHigh如果嚴重級別別高的話,應應提高警惕CorrectiveAction,Responsibility,andMonitoringResults實施糾正措施施,確定責任任人,監(jiān)控結結果1112DetectionRatingChart檢測等級表SummarizedRatingChart總結等級表SummaryofFMEASteps

FMEA步驟匯總FormaMulti-functionalTeam組建多功能小小組FailureMode:HowCouldThisPart,SystemorProcessFail?失效模式:該該產(chǎn)品,系統(tǒng)統(tǒng)或工藝是怎怎么失效的?EffectoftheFailure:WhatDoestheCustomerExperienceAsaResultoftheFailure?失效影響:作作為一種失效效模式客戶的的經(jīng)驗是怎樣樣的?CauseofFailure:WhatConditionsCouldBringAbouttheFailureMode?失效原因:關關于該失效模模式會導致什什么情況?Occurrence:ProbabilitytheFailureModeWillOccur發(fā)生:發(fā)生失失效模式的可可能性Severity:WeighingtheConsequenceoftheFailureMode嚴重性:衡量量失效模式的的結果Detection:ProbabilitytheFailureModeWillNotBeDetectedBeforeReachingtheCustomer失效:失效模模式在到達客客戶之前不會會被檢測到.RiskPriorityNo.(RPN):ProductofOccurrence,SeverityandDetection,ThatProvidesRelativePriority.風險號(RPN):產(chǎn)品發(fā)生頻率率,嚴重性檢檢測,提供了了相對優(yōu)先權權.IdentifyActionItems,AssignResponsibility,andFollowThrough確定實施措施施:分配責任任,跟蹤執(zhí)行行EssentialStepsforErrorProofing防錯的基本步步驟IdentifyOpportunitiesforErrors(CriticalFactors)PrioritizePotentialErrorsforProofingAbsolutelyMustPreventtheDefectsProvideContainmentandStudyFurtherMayBeTolerated,WithinPredefinedLimitsIdentifyRootCausesoftheErrorsDevelopandEvaluateErrorProofingOptionsSelectand““Design”theErrorProofingSystemImplement-Plan,Install,Document,Train,MonitorPeriodicallyAssessthePerformanceandImproveFMEAAddressesAlltheseErrorProofingStepsFMEA可以定位所有有的防錯步驟驟AndHelpsPlanforThese為此設置計劃劃Exercise-3

ProcessPFMEA過程PFMEA練習第三部分分IdentifyOneoftheProcessSteps識別一個過程程步驟WalkThroughtheStepsofPFMEA實施整個PFMEA步驟FillOuttheFMEAForm填寫FMEA表格DevelopanActionPlan開發(fā)實施計劃劃ErrorProofingOptions防錯方案ErrorProofingApproaches防錯方法EliminatePotentialDefects:DesignOutthePotentialsforErrors消除潛在缺陷:對對潛在錯誤進進行設計PreventDefectsFromOccurring:IdentifythePotentialofError,BeforeItOccurs,andPreventIt防止缺陷發(fā)生生:識別潛在在錯誤:在錯錯誤發(fā)生前進進行預防DetecttheDefect:ErrorHasAlreadyOccurred,DetectandRemovetheDefectiveProduct檢測缺陷:錯錯誤已經(jīng)發(fā)生生,檢測及移移除缺陷件LossControl:PotentialforDefectExists,PotentialExistsforNotDetecting,MinimizeDamageFromtheDefect損失失控控制制:存存在在潛潛在在缺缺陷陷,沒沒有有對對潛潛在在缺缺陷陷進進行行探探測測,使使缺缺陷陷的的傷傷害害最最小小化化.AllTheseApproachesOverlap,NoClearBoundaries所有有方方法法交交織織在在一一起起,沒沒有有清清晰晰界界限限Example-FireProofingaNewBuilding例如如-新新建建筑筑的的防防火火防防錯錯Eliminate:UseOnlyNon-combustibleMaterialforConstruction(Steel,Concrete,Etc.)排除除：：在在建建筑筑中中要要使使用用不不易易燃燃物物質質（（鋼鋼鐵鐵，，混混凝凝土土等等））Prevent:DoNotAllow不允允許許吸吸煙煙ElectricalSystemandComponents使用正正確的的電氣氣系統(tǒng)統(tǒng)和元元件預預防：：Detect:InstallSmokeDetectorsandFireAlarms檢測：：安裝裝煙霧霧檢測測器和和火警警系統(tǒng)統(tǒng)LossControl:InstallSprinklerSystem,FireExtinguishers,FireHoses損失控控制：：安裝裝自動動噴淋淋裝置置系統(tǒng)統(tǒng)，滅滅火器器，滅滅火水水龍帶帶，防防火軟軟管等等Example-AccidentProofaRailwayCrossing例子：測試試鐵道路口口的意外事事故EliminateAccidents:BuildaBridge排除事故：：建造一座座橋PreventAccidents:InstallanAutomaticGate,InAdditiontoLightsandAlarms預防意外事事故：除了了燈和警報報裝置,安安裝一個自自動門DetectandannounceaPassingTrain:InstallLightsandAlarms檢測和進進行一個個短期培培訓：安安裝燈和和警報裝裝置培訓訓LossControl,inCaseofanAccident:InstallaPayPhone??損失控制制，有意意外事故故時：安安裝一個個付費電電話??InManyCases,LossControlIsNOTanOption在很多情情況下,損失控控制不是是實施方方案FirstStepforErrorProofingOptions防錯的第第一個步步驟DecidetheLevelofErrorProofingNeeded需要決定定防錯的的水平Eliminate,If排除，如如果SeverityIsHigh嚴重度高高PotentialforOccurrenceIsVeryHigh發(fā)生的可可能性很很大DetectionIsImpossible檢測是不不可能的的CostofEliminatingisLow排除成本本低Prevent,IfDesignIsCompleted,and防止，如如果設計計完成SeverityIsLow嚴肅性較較低RPNIsLowRPM低AttemptDetectioninMostOtherCasesofPotentialforDefects對其他潛潛在缺陷陷進行檢檢測BasedonPriority以優(yōu)先權權為基礎礎OpportunitiesforErrorProofing防錯的良良機消除預防檢測損失控制制產(chǎn)品設計計工工藝/設設備設計計車間措施施其其他質質量保證證措施ErrorProofingDecisionDiagram防錯決策策圖表PotentialError潛在的錯錯誤DefectFreeProduct無缺陷產(chǎn)產(chǎn)品ErrorsEliminated排除錯誤誤PreventErrorfromOccurring防止錯誤誤發(fā)生EliminateDuringProduct/ProcessDesign在產(chǎn)品/過程設設計中消消除錯誤誤DetecttheDefect發(fā)現(xiàn)缺陷DefectDetected缺陷檢測DefectPrevented缺陷防止DesignLossControlIntheProduct在產(chǎn)品中設計計損失控制DefectHasSeriousConsequences缺陷導致嚴重重結果NoNoNoNo無Yes有YesYes有YesDevelopLossControlProcedure開發(fā)損失控制制程序KeyPointsforElimination錯誤排除的關關鍵點LargestPotentialDuringDesign設計中中的巨巨大潛潛能EliminatebyDesigningOutActivitiesWithPotentialforErrors對潛在在的錯錯誤設設計活活動,進行行排除除CostEffectiveIfAddressedBeforeFinalizingtheDesigns(Product,Process,Equipment)設計定定案之之前（（產(chǎn)品品，程程序，，器材材）計計算成成本效效用MostCostEffectiveMethodofAll大多數(shù)數(shù)成本本效用用方法法SixSigmaQualityCanBeAchievedOnlyWithExtensiveElimination只有完完成大大范圍圍消除除措施施后才才可以以完成成6SigmaMotorolaMandatesAllProcessesforaNewProducttoBeSixSigmaCapable摩托羅羅拉要要求所所有產(chǎn)產(chǎn)品工工藝都都可以以使用用6Sigma.OnceEliminated,NothingElseisRequired一旦消消除,就不不需要要其他他的了了ErrorElimination&Symmetry排除錯錯誤和和對稱稱L1L2L1L1MakeThemAsymmetric使其不不均勻勻分布布MakeThemCompletelySymmetric使其完完全均均勻分分布PartiallySymmetricParts部分均均衡件件OR或ErrorElimination&Dimensioning排除防防錯和和決定定錯誤誤大小小WhichisBetter?哪一個個最好好？AskWhatisImportantandHowItShouldbeMeasured什么是是重要要，應應怎樣樣測量量ToEliminateModifyorRedesign?通過修修改或或重新新設計計排除除錯誤誤?SomeDefectscanbeRemovedbyModifications許多缺缺陷都都可以以通過過修改改排除除OthersMayNeedRedesign其他許許多需需要重重新設設計KeyPointsforPrevention預防的的關鍵鍵點EliminationIsBestWaytoPrevent排除除是是最最好好的的預預防防方方法法RobustDesign精力力充充沛沛的的設設計計DesigntoTolerateUnavoidableVariations對不不可可避避免免的的變變化化進進行行設設計計EnsuresAcceptableProductsforWiderVariations確保?？煽梢砸越咏邮苁艿牡漠a(chǎn)產(chǎn)品品允允許許有有較較大大的的變變化化DesignSoThatErrorsCannotBeMade設計,以以免會產(chǎn)產(chǎn)生錯誤誤DesignProducts,Processes,Equipment,FixturesThatWillPreventWrongPartsFromBeingUsed(PokaYokeDevices)設計(PokaYoke裝置)產(chǎn)產(chǎn)品,工工藝,設設備,卡卡具等可可以防止止錯誤的的裝置.Procedures,Training,DocumentationThatHelpPreventErrors防止錯誤誤的程序序,培訓訓文件等等ErrorProofDocumentGeneratingProcesses-ThatWillPreventManyDefectsFromReachingtheCustomer防止錯誤誤的文件件-阻止止太多缺缺陷到達達客戶.Drawings,etc.圖紙等ReturnUnacceptableProductBacktothe““Supplier”把不合格格件返回回供應商商.InstitutionalizePreventionMindset結構化預預防措施施ConceptsforPreventionontheShopFloor車間預防防的理念念AlwaysProvideAidforCounting為計算提提供依據(jù)據(jù)HelpIndicateSelectionofParts幫助進行行零件選選擇ColorCoding,LightedIndicators彩色碼,彩燈指指示器ProvideOnlyWhatIsNeeded,PreventAccesstoOthers僅提供供所需需要的的,阻阻止進進入其其他部部分VerifyMachineSettingsThatControlCriticalDimensionsBeforeMachining驗證設備裝裝置等,可可以在加工工前控制標標準尺寸EmployTPMforEquipmentandDies設備及模具具可以實施施TPMImplementMechanismsThatHelptheOperators實施操作者者易使用的的機械裝置置BarCoding,CheckLists,GraphicWorkInstructions條碼,檢驗驗列表,圖圖表化的操操作說明InvolvetheOperators包括操作者者CarefullyDispositionRejectedParts仔細處理不不合格件AvoidRepetitive,Monotonous,HazardousTasks避免重復，，單調，危危險的任務務Standardize標準化DesignedtoPreventDefects預防防缺缺點點的的設設計計SensorstoDifferentiateIdenticalParts區(qū)別別可可互互換換零零件件的的傳傳感感器器L1L2AlmostIdenticalParts幾乎乎是是可可互互換換零零件件CoordinatedLightSensorsDifferentiatetoPreventErrors用燈燈傳傳感感器器來來區(qū)區(qū)分分預預防防錯錯誤誤DetectPresenceorAbsencetoPreventDefects使用用存存在在或或不不存存在在缺缺陷陷的的方方法法預預防防缺缺陷陷VerifyPresenceofScrewstoPreventAssembliesWithoutScrews確定定螺螺絲絲的的存存在在來來預預防防裝裝配配忘忘記記螺螺絲絲DetectSplicetoHelpDiscardtheSection探測接口幫助助廢棄某部分分VerifyLiquidLeveltoPreventShippingUnfilledBottle確認液體水平平,來預防未未裝滿瓶子運運走VariousTypesofCounterstoPreventDefects各種型號的計計算器來防止止缺陷2134BreakingtheLightCurtain斷掉燈的線路路LightReflectingSensors燈光反映感應應器InductanceSensors自感應器KeyPointsforDetection探測的關鍵點點PokaYokeDevicesCanAddressMostoftheManufacturingDefectsPokaYoke裝置可以探測測大多數(shù)生產(chǎn)產(chǎn)缺陷的位置置DetectionTakesCareofWhatWasNotPreventedUpstream,orintheCurrentProcess可以探測到以以前沒有預防防住的點,或或現(xiàn)場工藝中中的錯誤DetectionShouldTarget“Direct”Parameter,Examples:探測需定位正正確的參數(shù),例如:MeasurePressureUndertheNut,NottheTorque測量螺母下面面的壓力,而而不是扭矩下下面的壓力MeasureWeldStrength,NotWeldingCurrent測量焊接件的的強度,而不不是焊接件的的電流DetectionMustBeClosetotheProcess探測必須接近近工藝RightBeforeforIncomingParts進件以前前正確RightAfterforCompletedActivity完成活動動以后正正確DetectionShouldRejectUnacceptableParts&ProvideImmediatefeedback(PokaYokeDevices)探測應拒拒收不合合格件&立即提提供反饋饋(PokaYoke裝置)DetectionShouldBeReliable,CertifiableandMonitored探測須是是可靠的的,有保保證的,可以監(jiān)監(jiān)控的.MeasureDimensions(Go,NoGo)toDetectDefects測量尺寸寸(通止止規(guī))來來探測缺缺陷MeasureSheetThickness測量鋼板板厚度MeasureDiameter測量直徑徑MeasureSheetWidth測量鋼板板寬度DetectDifferentFeatures探測不同同的特性性DetectPickupofaSheet探測鋼板板位置DetectPresenceofFeatures探測特性性的存在在性DetectColorAccuracy探測顏色色精確性性DetectionUsingContact使用接觸觸探測RememberThisPart?是否記得得這個零零件?WhattoDoIfItCannotberedesigned?如果不能能重新設設計怎么么做FixtureDesignedtoDetectIncorrectOrientation設計卡具具檢測位位置正確確性DetectingDimensionUsingContact用接觸法法測定尺尺寸Accept可接受件Reject廢棄件GoodPart合格件BadPart不合格件件KeyPointsforLossControl損失控制制的關鍵鍵點Design,IntheProduct,AvoidanceofCatastrophicResults在產(chǎn)品設設計中避避免大的的損失SeveralBackupSystemsinAircraft,EjectionSeats,Parachute航行器,排除座座,降落落傘的備備份系統(tǒng)統(tǒng)Airbag安全氣袋袋LimitedClinicalTrialsonHumansofNewDrugs新藥物對對人進行行臨床實實驗FinalFunctionalTests,BeforeShipping運輸前的的最后功功能實驗驗NothingDetectedonIndividualParts不對單獨獨件進行行檢驗ScheduledMaintenanceChecksofMissionCriticalItems對于關鍵鍵項目任任務提供供定期維維修ShouldBetheLastResort對關鍵物物品進行行定期維維修檢驗驗,應該該有檢驗驗報告DriversDoGetinAccidents,SaveThemWithAirbags司機遇到到交通事事故時,安全氣氣囊可以以對他們們進行保保護NOTDesignUnsafeCars不要設計計不安全全的汽車車EarlyCommunication,RecallsAreExtremelyImportantforLossControl早期交流流,招回回對損失失控制是是非常重重要的TraditionalQualityControlVersusErrorProofing傳統(tǒng)的質質量控制制與防錯錯進行比比較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),完完成產(chǎn)品品實驗及及檢驗ErrorProofing,VerifyAfterEveryOperation&反饋每一序后后以及反反饋后進進行防錯錯確認DetectionVersusPrevention探測與預預防的比比較TraditionalQualityControlVersusErrorProofing傳統(tǒng)的質質量控制制與防錯錯進行比比較TraditionalQUALITYCONTROL傳統(tǒng)質量量控制InspectorTestFunctionalitytoDetectDefectiveproduct(FinalProductDefect)功能檢測測及實驗驗來探測測缺陷產(chǎn)產(chǎn)品(最最后產(chǎn)品品缺陷)TheTestProduces““Accept”““Reject”Judgement通過實驗選選出合格件件與不合格格件TestorInspectAfterSeveralOperations幾序以后進進行實驗與與檢測DifficulttoPinpointCauseoftheDefect精確找出缺缺陷原因很很困難NoDirectfeedbacktotheOffendingOperation對于不穩(wěn)定定序沒有直直接反饋LongDelayBetweenError&DiscoveryofDefect錯誤產(chǎn)生與與發(fā)現(xiàn)缺陷陷之間拖延延太長ErrorProofing防錯VerifySpecificCharacteri-stic&PreventErrororDetectInter-processDefect確定具體的的防錯以及及工藝缺陷陷預防Verification““Catches”DefectiveComponent確認捕捉缺缺陷件VerificationIsImmediate立即確認RelationofDefect&ErrorIsAlreadyKnown缺陷與錯誤誤之間的關關系已知道道FeedbackIsImmediate立即反饋NoDelayinDefectDiscovery不能拖延缺缺陷件的發(fā)發(fā)現(xiàn)TraditionalQualityControlVersusErrorProofing-Results傳統(tǒng)的質量量控制與防防錯進行比比較-結果果Op1Op2Op3Op4Test/Inspect實驗/檢測Scrap廢品Accept合格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),完成成產(chǎn)品實驗驗及檢驗ErrorProofing,Verify確定AfterEveryOperation&反饋每一序后以以及反饋后后進行防錯錯確認99.6%99.9%99.9%99.9%99.9%99.9%99.9%99.9%99.9%99.9%TypesofChecks/Verifications檢驗/確認認類型