防誤措施分析

MISTAKE-PROOFING

防誤措施AchievingCompetitiveExcellence-獲取競爭性優(yōu)勢

ACEElementsQCPCRootCause/CorrectiveActionPassportProcessManagementStandardWorkMistakeProofingMarketFeedbackAnalysisNew6SQualityClinicActivityTPM

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)通行證程序管理標榜化作業(yè)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ACEElementsEngineeringNewProducts,Processes&SystemsPassport-Systematicmethodforreview/approvalofnewdesigns

StandardMethod

ProcessManagement-Meanstoidentify&mapkeybusinessprocessesStandardWork-Repeatableprocessesthatareeffectiveandefficient

QualityImprovementMethodsQCPC-Simpletooltoidentifyproblemsandinefficiencies(turnbacks)

MFA-DatasummariesthatdisplayhowcomponentsperforminfieldRootCause-Methodtodrivetothetruesourceofproblems

StandardEnvironmentNew6S-WorkplaceorganizationandvisualcontrolTotalProductiveMaintenance-Continuouslyimprovingequipment effectiveness/availability Mistake-Proof-Creationofdevicesthatensureataskisalways donecorrectlyACE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–識別并展示重要商業(yè)程序的方法

標準化作業(yè)-可重復(fù)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(wù)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Improvecustomersatisfactionandqualitybyeliminatingescapes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(wù)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Pumpingdieselfuelintoyourgastank.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(fù)印機的進紙?zhí)幉⒄鏇_下orMisunderstandingrequirements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MostCommonMistakes

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-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalways

donecorrectly.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(wù)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(fù)性的任務(wù)Complexinstructions復(fù)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？Topreventturnbacksandcustomerescapes

fromrecurring,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andit’sfoundhere,并在這兒被發(fā)現(xiàn)，

itcosts:

就要花費：Rework,repair,scrapandescapescostUTC$148millionperyear.Warrantyexpensescostusanother$600millionperyear.Thecostoflostcustomerloyaltyduetoescapesisimmeasurable.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。Design設(shè)計Develop

Process進行加工Op2Customer客戶Op1Op1Op2$1$10$100$1,000$10,000Mistake-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,characteristicsorsupplier改變組件的類型、特征或供應(yīng)商2ApproachestoMistakeProofing

預(yù)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： Coffeemakerwasredesignedtomeasureandaddthepreciseamountofwaterfromawaterbottle 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。Recessin

chassis底盤的凹槽Label標簽ModelT6AC110V10WAfterImprovement: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。Recessin

chassis底盤的凹槽Label標簽ModelT6AC110V10WExampleofMistake-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：Thesocketextensionrequiredtoreachtheboltscausednicksandscratchesinthepaintedsurfacesthatitcontactedduringassembly.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-Proofingisawayofusingwisdomandingenuity

tocreatedevicesthatensureataskisalwaysdonecorrectly.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(wù)總是能正確完成的設(shè)備的方法。Mistake-Proofingisn’tWords!

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)（由緊急服務(wù)部填寫）(filledoutbyemployee)（由雇員填寫）TrueMistake-Proofing真正的防誤措施1DayBadge#1日證件號AllgrayareasfilledoutbyEmergencyServices所有灰色區(qū)域由緊急服務(wù)部填寫EmployeeClock#雇員鐘點號AllyellowareasfilledoutbyEmployee所有黃色區(qū)域由雇員填寫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Improvetheprocess!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Moveresponsibilityandauthoritydownintheorganization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Don’tjustsitandthinkaboutsolutions...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”）Whenyouthinkyou’vegotthebestsolution…TRYTOMAKEITFAIL!!!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(yīng)放棄Ensurethemistake-proofdoesn’tcreateanotherproblem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Noticemistakeasithappens當錯誤發(fā)生時要留意Developasimplefixtopreventitfromrecurring.開發(fā)出一種簡單方法來防止它再發(fā)生Implementthesimplefixintothestandardprocess在標準程序中運用這種簡單方法UseQCPCtocollectTurnbackdata使用QCPC來收集缺陷數(shù)據(jù)UseParetoAnalysistoIdentifytopturnbacks用Pareto分析來識別最高缺陷率PerformRootCauseAnalysistoidentifyRootCause用根本原因分析來識別根本原因Develop&implementMistake-Proofs

topreventrecurrence.開發(fā)并執(zhí)行防誤措施來防止錯誤的再發(fā)生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) LevelII: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(changingthede