Building a Defect-Free Work Environment 無錯環(huán)境制造

BuildingaDefect-FreeWorkEnvironment

無錯環(huán)境制造MistakeProofing防錯PokaYoke防錯Pokayokeshouldnot防錯不應Beexpensive….昂貴Takeawayfromoperatorintegrity….(training)員工不認真（培訓）Bedifficulttouseto(heavyorcumbersome).很難使用（太重或太麻煩）Forgottenaboutafterit’sinstalled.安裝以后忘記使用Complexinnature.本身復雜Poka-Yoke防錯Whatdoesitmean?它意味著什么？IntheJapaneseLanguage,Poka-Yokestandsfor:用日本話防錯表示：Yokeru–Avoid;避免Poka–InadvertentMistakes不注意的錯誤ThemostcommontranslationisMISTAKEPROOF.最普通的翻譯為防錯。MistakeProofing–PokaYoke

防錯－PokaYokeDefinition定義Usingwisdomandingenuitytoprovidemethodsanddevicesthatallowyoutodoyourjob100%defectfree100%ofthetime.使用聰明和智慧提供方法和設備使你在100％時間內(nèi)使工作100％無錯發(fā)生。MistakeProofingPhilosophy防錯思想Recognizethatpeople,machines,andprocessesmakeerrors認識到人、機器及過程會制造錯誤Respecttheintelligenceofworkersbyremovingthejudgmentfromrepetitivetasksoractionswhereerrorsarelikelytooccur通過不需員工進行重復性任務或活動可能發(fā)生錯誤的判斷來尊重員工聰明才智。Usesimpleandcreativemistakeproofingideastoovercomehumanandmechanicalerrors使用簡單及創(chuàng)造性防錯的思想來克服人及機器上的錯誤Donotaccept“operatorerror”asanexcuseforrootcauseofaproblem不能接受將人的錯誤作為原因的借口。Establisha“zerodefects”standard建立“0缺陷”標準Creatingthe“zerodefect”standardandreachingthezerodefectsobjectiveiseveryone’sresponsibility產(chǎn)生0缺陷標準及達到0缺陷目標是每個人的責任DEFECT缺陷ErrorsvsDefects錯誤及缺陷ERROR錯誤Leavetheirononthenleaveforwork將烙鐵放在火上，然后去做（其他）工作Pumpdieselfuelintoyourgastank將柴油抽入你的氣缸中Runaredlight

亮紅燈Setthetimerimproperlyonyourtoaster在烤面包機上不適當設置定時器Placethe“original”inyourcopier“faceup”將“原作”向上放入復印機Runoutofinkonyourdatecoder日期碼用完了墨FIRETheyarenotthesamething!他們不是一回事！Defectsaretheresults!缺陷是結果！Errorsarethecausesoftheresults!錯誤是結果的原因！Whenanyoftheconditionsforsuccessfulprocessingarewrongorabsent當成功的處理條件發(fā)生錯誤或缺少時TenMostCommonErrors十個最普通的錯誤Processingomissions處理疏忽Processingerrors處理錯誤Errorinsettinguptheworkpiece設置工作時錯誤Assemblyomissions組裝疏忽Inclusionofwrongpart/item包含有錯誤的零件/物品Wrongworkpiece錯誤的工件Operationserrors員工錯誤Adjustment,measurement,dimensionalerrors調(diào)整測量，尺寸錯誤Errorinequipmentmaintenance設備維護的錯誤Errorinpreparationofblades,fixtures,ortools準備刀、夾具或工具時的錯誤Conditionthatdoesnotmeetcustomerrequirements不滿足客戶需求的條件CommonDefects一般性錯誤Leaks滲漏Miswire

錯線Looseparts零件松Noise聲音Damagedparts/product損壞件/產(chǎn)品Reversedparts/product相反件/產(chǎn)品Foreignmatterpresent異物出現(xiàn)Mismatchedparts不配件Misalignedparts不呈一條線零件Wrongorinconsistentdimensionality有錯誤或不連續(xù)的維度Unabletobeassembled不能組裝Inconsistenttestresults/testfailure不連續(xù)的測試結果或測試失敗Badincomingmaterial不良來料Wrongmaterialorparts錯誤的材料或零件Poorcopies拷貝不清楚Wrongnumber數(shù)字錯誤Wrongentryonform表格上錯誤輸入Misfiled歸錯文檔Other...其它CausesofHumanErrors人錯原因Errorsinidentification識別錯誤Errorsduetoworkforceturnover由于勞動人員轉(zhuǎn)換導致的錯誤Errorsduetoshortcuts由于走捷徑而導致的錯誤Errorsduetolackof,orinadequate,standards由于缺少或不充分的標準而導致的錯誤Intentionalerrors有意的錯誤TwoApproachestoHumanError

針對人力錯誤的兩種方法Peoplemakemistakes

個人制造錯誤Placeblame

責備Detectatfinalinspection最后檢驗探測Samplinginspection

抽樣品檢驗Somereachthecustomer

一些達到客戶標準Eliminatethepossibilityofthemistake

消除錯誤可能性Eliminatetheconsequenceofthemistake

消除錯誤原因Askwhytheprocessfailed

問為什么過程會失效Applymistakeproofingdevicefor100%inspectionoreliminatetheerror應用100％的防錯設備檢驗或消除錯誤Nodefectsgetgenerated

無錯產(chǎn)生ConventionalApproach傳統(tǒng)方法MistakeProofingApproach防錯方法ErrorsAreInevitable錯誤時不可避免的ErrorsCanBeEliminated錯誤可以消除Machine/EquipmentError機器/設備錯誤Drillsbreak鉆裂Inadequateairpressuretotorqueguns

氣槍不充足的氣壓Toolsbecomedull工具變鈍Locatorsonfixtureswear

夾具磨損定位器問題Poorelectricalconnections

不好的電子連接器Recognizethatmachinesmakeerrors認識到機器會制造錯誤Establisha“ZeroDefects”Standard

建立一個“0缺陷”的標準If99.9%wereacceptable,youwouldn’tmindif…如果99.9％是可能接受，你將會不介意如果…Connecticutpostofficeswouldlose10,271piecesofmailperday康涅狄格郵政局每天將丟失10.271封郵件O’HareInternationalAirportwouldhave1,264unsafearrivals/departuresperyearO’Hare國際機場每年將有1.264次不安全的到達/離開DoctorsatNewYorkstatehospitalswoulddrop288newbornbabiesperyear紐約醫(yī)院的醫(yī)生每年將掉下288新生嬰兒OurResponsibility我們的責任Wehavethisresponsibility:createthe“zerodefects”standardandreachingthezerodefectsobjective我們有責任產(chǎn)生“0缺陷”的標準及達到“0缺陷”的目標Measure-

mentMaterialMachineMeMethodNew5S新的5STPMQCPCProblemSolvingPDCA解決問題Mistake

Proofing防錯“Zero

Defects”0缺陷SummaryofMistakeProofingPhilosophy

防錯思想總結Mistakesareaninherentpartofaprocess錯誤是一個過程的固有部分Mistakescanbecontrolled防錯可以控制Zerodefectscanberealized可以實現(xiàn)0缺陷Wemustbecommittedtozerodefects我們必須承諾做到“0缺陷”WhyFocusonMistakeProofingforZeroDefects?

為什么關注0缺陷的防錯？Profitability可獲利Productivity有生產(chǎn)力LeanProductionSystems(JIT)

精益生產(chǎn)系統(tǒng)CustomerSatisfactionandLoyalty

客戶滿意及忠誠“Wecanensuredefect-freeshipmentstoourcustomersthroughinspection”DefectEliminationFallacies消除缺陷的錯誤Mechanicalgaugeinspection機械規(guī)則檢查100%visualinspection100％目視檢驗Firstpiece/lastpieceinspection首末件檢查Sampling,n=?抽檢Statisticalsampling統(tǒng)計抽樣100%inspectionensuresdefect-freeshipments100％檢查確保無缺陷發(fā)運Defectsareinevitable缺陷不可避免Inspectionsreducedefects檢驗降低缺陷Does100%InspectionFinds

100%oftheRejects

100%oftheTime?FINISHEDFILESARETHERE-

SULTOFYEARSOFSCIENTIF-

ICSTUDYCOMBINEDWITH

THEEXPERIENCEOFYEARS.PleasefindandcountalltheF’sonthispage.Exercise練習Conclusions結論Youcannotinspectqualityintoaproduct

你不能把質(zhì)量檢驗到產(chǎn)品中去Youcannotinspectbadqualityoutoftheproduct

你不能在產(chǎn)品之外檢驗不好的品質(zhì)Ifstatements1and2aretrue,andwetrulydesirezerodefects,theonlyalternativeistomaketheproductdefect-free.

如果1和2是正確的話，我們真正希望0缺陷唯一的選擇是做0缺陷的產(chǎn)品。GuidelinesforMistakeProofingImplementation

實施防錯的原則Describedefect描述缺陷Identifyoperationinwhichdefecthappenedandwhereitisfound識別缺陷發(fā)生及發(fā)現(xiàn)的操作Describedesignatedprocedure描述規(guī)定的步驟Watchandnotedifferences觀察和注意差距Identifyredflagconditions識別紅旗狀況Identifyerrorsandaskwhyfivetimes

識別錯誤及問五個為什么Brainstormandidentifymistake-proofsolution

腦力激蕩及識別防錯方法Try-stormsolution試－哪些腦力風暴方法Describewhatdidhappen描述已發(fā)生什么PerformProblemSolving

Ask5Whys實施解決問題問5個為什么TryStorm試頭腦風暴方法ApplyNastyTest應用步驟測試MonitorresultswithQCPCorSPC用QCPC控制結果壓迫零件控制過量控制或SPCDescribewhatshouldhappen描述發(fā)生了什么(Proactive)

Identify

RedFlag(主動地）識別紅旗

DevelopMistakeProofingDevice開發(fā)防錯設施MistakeProof

Design防錯設計(Reactive)Describedefectorproblem(QCPC)（反應式）地描述缺陷或問題（QCPC)IdentifyGapand

RedFlags識別差異及紅旗ShareLessonsLearned分享經(jīng)驗MistakeProofingImplementationChart

防錯實施圖RedFlag紅旗REDFLAG紅旗ERROR錯誤DEFECT缺陷Aconditionintheprocessthatcommonlyprovokeserrors過程中通常引起錯誤的狀況RedFlagConditions紅旗狀況Adjustment調(diào)整Tooling/toolingchange工具/工具改變Dimensionality/specification/criticalcondition維度/規(guī)格/關鍵狀況Manyparts/mixedparts很多件/混合件Lackof,orineffectivestandards標準缺少或無效Environmentalconditions環(huán)境狀況改變Multiplesteps多步Hiddenparts隱藏件Symmetry對稱Asymmetry不對稱Rapidrepetition快速重復Highvolume/extremelyhighvolume量大/量巨大Infrequentproduction不頻繁生產(chǎn)FourElementsofMistakeProofing&Examples

防錯及例子的四個部分SourceErrorReview檢查錯誤源Sensorchecksforbrokendrillbitpriortodrillingsmalldiameterholeinautomatedprocess在自動化過程中鉆小直徑孔前傳感器檢查破損鉆頭100%PartVerification100％零件驗收Sensorchecksforpresenceofsmalldiameterholeafterdrillinginautomatedprocess在自動化過程中鉆孔后傳感器檢查小直徑孔的外表Element部分內(nèi)容Example例子Description描述Discoversandcorrectbeforetheyresultindefects在他們生產(chǎn)不良前發(fā)現(xiàn)或校正Internaltotheoperationandatnoadditionalcost,checksallproducts,notjustasample從內(nèi)構件到操作無額外成本，檢查所有產(chǎn)品而不是樣品PromptFeedbackandAction立即反饋及行動SensorhasinterlockedcircuitthatautomaticallyshutsdownthedrillpresswhenthedrillbitisbrokenortheholeismissingElementExampleMistakeProofingDevices防錯設施Sensorandinterlockcircuits傳感器及自鎖環(huán)路FourElementsofMistakeProofing&Examples

防錯及例子的四個部分DescriptionShortenstimeforcorrectiveaction縮短校正行動的時間Performsthesourceerrorreview,100%partverification,andpromptfeedbackfunctions完成錯誤源頭檢查，100％零件驗證及立即反饋功能RequirementforSuccess成功要素Anenvironmentthat…一個環(huán)境…Recognizespeoplewanttodoqualitywork認識到人想做好質(zhì)量工作Promotesinvolvementandcreativity促進參予及創(chuàng)造性Providestimeandsupportresourcestosolveproblems提供時間解決問題及支持資源Strivesforcontinualimprovement致力于持續(xù)改善ThreeLevelsofMistakeProofing

防錯的三層級水平Level1:Preventanerrorfromoccurringatthesource水平1：從源頭發(fā)生處防止錯誤Level2:Detecterrorasitisbeingmade水平2：正在做時探測到錯誤Level3:Preventthedefectfromreachingthenextoperation水平3：在對到達下一操作前防止缺陷品TypesofMistake-ProofDevices

防錯設施的類型Guide/reference/interferencerodorpin*引導/參考/干涉棒或針Alarm*警告Limitswitch/microswitch*限制開關/微動開關Counter*計數(shù)器Checklist*檢查表Template欄板Odd-part-outmethod多余件方法不對Sequencerestriction順序限制Standardizeandsolve標準化及解答（開）Criticalconditionindicator嚴格的狀態(tài)指示Stopper/gate停止線/門Sensor傳感器Detectdeliverychute探測運輸滑道*MostcommonlyusedDescription:PositionedJ-Retainer,guaranteesseamwidth.描述：定位性J固定器，保證縫寬Sewingguide.Theprofileshapekeepsplasticpartalignment.縫紉引導，輪廓形狀保持塑料件平齊Detail細部Guide/Reference/InterferenceRod

引導/參考/干涉棒TorqueGun力矩槍Reproduceandandrepeatthesametorqueoverandoveragain.Removingthejudgmentfromrepetitivetasksoractionswhereerrorsarelikelytooccur一次又一次地產(chǎn)生并重復一樣的力矩，從重復性任務或活動中清除判斷可能發(fā)生錯誤的Checklist檢查表Preflightpilotchecklist起飛前的飛機檢查表“ToDo”lists“要做的”清單Inspectionchecklists檢驗檢查表SuccessfulMistake-ProofDevices

成功的防錯設施Youshouldbeabletoansweryestoallofthese:你應該針對所有下列問題回答YES：Isitsafetouse?(EH&S)它安全使用嗎(EH&S)？Preventsreoccurrence?預防再發(fā)生嗎？Inexpensive?不貴嗎？Simpletouse?使用簡單嗎？Easytoimplement?易于實施嗎？Durable?耐久嗎？Easytomaintain?易于保持嗎？Doesnothinderoperator?不阻塞嗎？Givespromptfeedback?立即反饋嗎？Givespromptaction(prevention)?立即動作嗎（預防）？Hastherightpeople’sinput?正確人員的輸入？Reliable—doesnotgivefalsesignals?可靠－沒有發(fā)生錯誤信號？NastyTests粗略測試Devicesaremonitoredforeffectivenessandaremaintainedinsoundworkingcondition設施有效監(jiān)控及保持在良好狀態(tài)Validatesthebestdevice求證為最好設施Mistake-proofdevicesneedtobe100%reliable防錯設施需要是100％可靠Ifyoureceivefalsereadings,youwillnotbelieveyourdevices如果你收到錯誤記錄，你將不能相信你的設施Whendoingthetest,theoperatormustseeiftheycanfailthedevice在做測試時，員工必須看清是否實施會失效HowDoWeRecognizeSuccess?我們怎樣認識成功？DescriptionofProcess:Nutsaretightenedwithaspecifictorquewithapowerwrenchdrivenbypneumaticpressuresuppliedthroughoutthefactory.過程描述：用工廠提供的氣壓驅(qū)動動力扭力槍在一定力矩下固定螺母。BeforeImprovement:

Ifai