研發(fā)項(xiàng)目管理培訓(xùn)材料差錯(cuò)預(yù)防

MistakeProofing差錯(cuò)預(yù)防楊振宇（MikeYoung）LMRoadMap精益管理實(shí)踐路標(biāo)

全面生產(chǎn)維護(hù)TPM統(tǒng)計(jì)過程控制

精益系統(tǒng)導(dǎo)入

現(xiàn)場(chǎng)改善

流線化設(shè)計(jì)

直觀化管理

看板管理

快速換模SMED

標(biāo)準(zhǔn)化作業(yè)均衡生產(chǎn)5S與質(zhì)量意識(shí)時(shí)間與動(dòng)作分析精益物流價(jià)值流圖析VSM差錯(cuò)預(yù)防精益成熟度評(píng)估生產(chǎn)準(zhǔn)備流程精益促進(jìn)者培訓(xùn)問題防止StrategicQuestions戰(zhàn)略問題Doesyourorganizationseetheachievementofzerodefectsasarealisticgoal?

你的組織是否看到把零缺陷作為實(shí)際的目標(biāo)所產(chǎn)生的巨大成就？Doesyourorganizationvaluezerodefectsasnecessarytolong-termsuccess?

你的組織是否把零缺陷看作是長期成功的必然要素？SectionOne:第一部分

WhyUseMistakeProofing?為什么要使用差錯(cuò)預(yù)防Definition：mistakeproofing差錯(cuò)預(yù)防的定義What‘sholdingyouback?是什么在阻礙你們？Value-addingandnonvalue-adding增值與非增值作業(yè)分析Aparadigmshift一種觀念的突破Benefitsofmistakeproofing差錯(cuò)預(yù)防的好處Definition:定義MistakeProofing:差錯(cuò)預(yù)防Aprocessimprovementsystemthatpreventsfaultyproductsandavoidsthecostsrelatedtothedispositionandtrackingofdefects.

一個(gè)防止產(chǎn)生有缺陷的產(chǎn)品并避免相關(guān)處理以及追溯缺陷所造成的代價(jià)的過程改善系統(tǒng)What'sHoldingYouBack?

是什么阻礙了您？Whatpreventsyoufromachievingperfectquality?A.K.A.“ZeroDefects”

什么阻礙你獲得“零缺陷”的完美品質(zhì)？Issues放行Practices習(xí)慣Attitudes態(tài)度Policies政策Otherobstacles其他障礙FiveElements五個(gè)要素質(zhì)量問題常常藏身在上述五個(gè)因素中，改善需要對(duì)其根源原因進(jìn)行分析Operator人Materials物料Machines設(shè)備Information信息Method方法FourMajorFactorsinProduction

Flow生產(chǎn)流程中的四個(gè)主要因素Transformation轉(zhuǎn)換Inspect/Rework檢驗(yàn)/返工Transport搬運(yùn)Store存儲(chǔ)Lookingatthesefactors,wecancreateadefinitionofwaste.這些因素中包含著浪費(fèi)ProcessandOperation流程與運(yùn)作ABCNInspect-Non-Value-AddingOperation檢驗(yàn)—非增值作業(yè)Transform-Value-AddingOperation變形—增值作業(yè)Transformation變形Inspect/Rework檢驗(yàn)/返工Transport運(yùn)輸Store儲(chǔ)存PROCESS增值-VA非增值-NVADefinition定義Non-Value-AddingProcess:非增值過程Thoseprocessstepsthattaketime,resources,orspace,butdonotaddvaluetotheproductorserviceitself.雖然占用了資源、空間及節(jié)拍時(shí)間，但對(duì)產(chǎn)品或服務(wù)本身而言不增加價(jià)值Value-AddingProcess:增值過程Anactivitythattransformsorshapesrawmaterialsordatatomeetcustomers’requirements.為滿足顧客需求而使原材料發(fā)生形變或數(shù)據(jù)轉(zhuǎn)換活動(dòng)ProcessTime流程時(shí)間95%oftheactivitiesrelatedtoagivenprocessdonotaddvaluetotheproduct.95%的管理活動(dòng)是不增值的。NVA5%VATotalManufacturingLeadTime全部生產(chǎn)交付時(shí)間95%InspectiontoDiscoverDefects

為了發(fā)現(xiàn)缺陷而檢驗(yàn)Productsarecomparedwithstandardsanddefectiveitemsareremoved

和標(biāo)準(zhǔn)進(jìn)行對(duì)比，有缺陷的被拿走Samplinginspectionisusedwhen100%inspectionistoomuchtrouble

全檢太麻煩的時(shí)候采用抽樣檢驗(yàn)Assumptions假設(shè)Defectsareinevitable缺陷不可避免Morerigorousinspectioncan"reduce"defects

更多嚴(yán)格的檢驗(yàn)?zāi)堋皽p少”缺陷InspectiontoReduceFutureDefects

為了減少未來的缺陷而檢驗(yàn)Statisticalqualitycontrolactivities"inspect"processestoanticipateandavoiddefects.

統(tǒng)計(jì)質(zhì)量控制扮演“檢驗(yàn)”的角色，用以預(yù)期和避免缺陷。Basedonstatisticalanalysis,teamseliminatespecialcauses(processcontrol)andreducevariation(processcapability).

基于統(tǒng)計(jì)分析的結(jié)論，團(tuán)隊(duì)消除特殊原因（過程控制）以及減少變異（過程能力）。Assumptions假設(shè)Somelevelofdefectsisinevitableandacceptable.

一些等級(jí)的缺陷是不可避免并且是可接受的。Focusisonresultsratherthancauses.

聚焦在結(jié)果而不是原因。Inspection檢驗(yàn)Althoughitisnecessarytohaveefficientinspectionoperations,theyareoflittlevalueintheprocess.Eventhemostefficientinspectionoperationsaremerelyefficientformsofwaste.

盡管有效的檢驗(yàn)是必須的，但它們對(duì)流程僅有很小的價(jià)值，甚至大部分的檢驗(yàn)只是一種有效率的浪費(fèi)形式。Inspectionplaysapassiveroleinproduction-byitselfitcannotreducedefects.檢驗(yàn)不可能減少缺陷Benchmarking你能接受這樣的標(biāo)桿嗎？Whatdoes99%OKora3.8Sigmalevelmean?200,000Wrongdrugprescriptionseachyear

每年開錯(cuò)200000個(gè)藥物處方20,000Lostarticlesofmailperhour

每小時(shí)弄丟20000個(gè)郵包5,000Incorrectsurgicaloperationsperweek

每周5000個(gè)手術(shù)做錯(cuò)2Crashlandingsatmostmajorairportseachday

每天在大部分重要的機(jī)場(chǎng)有2架飛機(jī)墜毀Howabout99.9997%ora6Sigmalevel?68Wrongdrugprescriptionseachyear每年開錯(cuò)68個(gè)藥物處方7Lostarticlesofmailperhour每小時(shí)弄丟7個(gè)郵包1.7Incorrectsurgicaloperationsperweek每周1.7個(gè)手術(shù)做錯(cuò)1Crashlandingevery5years

每5年有1架飛機(jī)墜毀ParadigmShift

觀念突破Toreducedefectswithinproduction,wemustrecognizethatdefectsaregeneratedbytheworkandallinspectionscandoisdiscoverthosedefects.為了減少缺陷，我們必須認(rèn)識(shí)到缺陷是作業(yè)產(chǎn)生的，而所有的檢驗(yàn)?zāi)茏龅膬H僅是發(fā)現(xiàn)它們BenefitsofMistakeProofing

差錯(cuò)預(yù)防的好處Enforcesoperationalproceduresorsequences.

確保運(yùn)作程序的執(zhí)行Preventsproductdamage.

防止產(chǎn)品缺陷Signalsorstopsaprocessifanerrorismadeoradefectiscreated.

當(dāng)一個(gè)錯(cuò)誤發(fā)生或缺陷產(chǎn)生時(shí)停止一個(gè)過程，或發(fā)出警告信號(hào)Eliminateschoicesleadingtoincorrectactions.

消除導(dǎo)致不正確操作的選擇Preventsmachinedamage.

防止設(shè)備損壞...AndinConclusion小結(jié)Mistakeproofingisaprocessimprovementsystemthat:差錯(cuò)預(yù)防是一個(gè)過程改善系統(tǒng)Preventsfaultyproducts

防止有差錯(cuò)的產(chǎn)品Preventsmachinedamage

防止設(shè)備損壞Mistakeproofinghelpsusachievezerowasteandzerodefects.

差錯(cuò)預(yù)防幫助我們實(shí)現(xiàn)“零浪費(fèi)”和“零缺陷”SectionTwo:第二部分TrackingDefectsToTheirSource追蹤缺陷到源頭Trackingdefects追蹤缺陷

Threetypesofinspection檢驗(yàn)的三種類型Mistakeproofingandzerodefects差錯(cuò)預(yù)防和零缺陷Zerodefectssystem

零缺陷系統(tǒng)Five-levelratingsystem五級(jí)評(píng)估系統(tǒng)TrackingDefects

缺陷追蹤Typicallywetrackdefectsby

通常我們用以下參數(shù)追蹤缺陷：Quantity數(shù)量Kind種類Percent百分比Witha"zerodefects"focuswemusttrack如果是零缺陷我們則必須追蹤：Thepointatwhichthedefectisdiscovered

缺陷被發(fā)現(xiàn)的位置Thepointatwhichthedefectoccurs缺陷發(fā)生的位置ThreeTypesofInspection

檢驗(yàn)的三種類型SelfChecks

自檢SuccessiveChecks

互檢SourceInspection

源頭檢驗(yàn)Definition:定義

SelfCheck:自檢Theoperatorperformingworkchecksitbeforepassingitontothenextprocess.Thisisself-inspectionbytheoperatorthroughsensoryandvisualcues.

操作者在向下道工序移交工作前進(jìn)行的工作檢查，一般靠感覺和視覺提示。Definition:SuccessiveCheck:互檢Theoperatorcheckstheoperationsthatwereperformedbythepreviousoperatorpriortoaddinganyvalueattheirstation.

操作者在工作開始前對(duì)前面操作者輸出的檢查。Definition:SourceInspection:源頭檢驗(yàn)Takingpreventiveaction,attheerrorstage,topreventerrorsfromturningintodefects--ratherthantakingcorrectiveactionafterdefectshaveoccurred.

在錯(cuò)誤發(fā)生階段進(jìn)行預(yù)防性檢查，防止錯(cuò)誤變成缺陷，而不是在缺陷發(fā)生后才進(jìn)行糾正措施。SourceInspection源頭檢驗(yàn)Cause原因Error錯(cuò)誤Action行動(dòng)Check&Feedback檢查與反饋Effect結(jié)果Defect缺陷Check&Feedback檢查與反饋Action行動(dòng)DefectDetectionCycle缺陷檢測(cè)環(huán)DefectPreventionCycle缺陷預(yù)防環(huán)MistakeProofingSystem差錯(cuò)預(yù)防系統(tǒng)100%Inspection全檢PromptFeedback&Action迅速反饋與行動(dòng)ZeroDefectsSystem零缺陷系統(tǒng)100%Inspection全檢PromptFeedback&Action迅速反饋與行動(dòng)ZeroDefects!零缺陷Error錯(cuò)誤Action行動(dòng)Check&Feedback檢查與反饋DefectPreventionCycle缺陷預(yù)防環(huán)Cause原因SourceInspection源頭檢驗(yàn)MistakeProofingSystem差錯(cuò)預(yù)防系統(tǒng)+=FoundationforZeroDefects

零缺陷的“地基”Physicalcheckingfunctionsincorporatedintotheoperation檢查功能與運(yùn)作融為一體ZeroDefects零缺陷Promptfeedbackandcorrectiveactionwherethedefectisgenerated.缺陷發(fā)生時(shí)迅速的反饋與糾正100percentvalidationofeachproductioncycle每個(gè)生產(chǎn)循環(huán)100%進(jìn)行確認(rèn)5LevelsofQualityAssuranceAchievement

五級(jí)質(zhì)量保證水準(zhǔn)評(píng)估Level水平Effect結(jié)果Inspection檢驗(yàn)ZDAction零缺陷行動(dòng)1Plantshipsdefectiveproducts工廠交付有缺陷的產(chǎn)品Lotsofdefectsandlotsofcustomercomplaints大量的缺陷與顧客抱怨None沒有Shutdownthefactory關(guān)閉工廠2Plantdoesnotshipdefectiveproducts工廠不交付有缺陷的產(chǎn)品Lotsofdefectsbutnocustomercomplaints大量的缺陷但沒有顧客抱怨Judgmentinspection判斷型檢驗(yàn)Usemoreinspectors使用更多的檢驗(yàn)員3Plantisreducingdefects工廠正在減少缺陷Defectsproducedinoneproductionrunarenotrepeatedinnextproductionruns同樣的缺陷不會(huì)重復(fù)發(fā)生Informativefeedbackinspection;SPC信息反饋型檢驗(yàn)統(tǒng)計(jì)過程控制Boostkaizenimprovements推進(jìn)改善4Plantprocessesdonotsenddefectsdownstream工廠設(shè)立不發(fā)送缺陷給下游工序的流程Whendefectsareproduced,theydonotgetpassedontothenextprocess缺陷不會(huì)流到下游工序successiveandself-checks自檢與互檢Trainoperatorstoidentifyandremovedefects對(duì)操作者識(shí)別和處理缺陷進(jìn)行培訓(xùn)5Plantprocessesdonotcreatedefects工廠設(shè)立不產(chǎn)生缺陷的流程Whenanerroroccurs,theprocessdoesnotproducedefects錯(cuò)誤不會(huì)產(chǎn)生缺陷Inspectionatthesource源頭檢驗(yàn)ZeroDefects,ZeroWaste,ZeroDelays零缺陷、零浪費(fèi)、零延遲WhereDoYouStand?

看看你在哪個(gè)水平？水平:結(jié)果:檢驗(yàn):ZD行動(dòng):…AndinConclusion小結(jié)Toachievezerodefects,weneedbothsourceinspectionandmistakeproofing.

為了獲得零缺陷，我們需要源頭檢驗(yàn)和差錯(cuò)預(yù)防SectionThree:第三部分ErrorsandDefects錯(cuò)誤與缺陷AnalysisofQualityProblems.

品質(zhì)問題分析Thedifferencebetweendefectsanderrors.

缺陷與錯(cuò)誤的差異Sampledefectsanderrors.

缺陷與錯(cuò)誤的例子AnalysisofQualityProblems

品質(zhì)問題分析Part#部件Defect缺陷Scrap/Rwk廢品/返工Found發(fā)現(xiàn)Made形成Time-Distance時(shí)間—距離Whatistheproduct?什么產(chǎn)品？Whatisthedefect?什么缺陷？Didthedefectresultinscraporrework?缺陷導(dǎo)致廢品還是返工？Wherewasthedefectfound?在哪發(fā)現(xiàn)缺陷？Wherewasthedefectmade?缺陷在哪形成？Thenumberofoperationsorhours?操作的數(shù)量或時(shí)間多少？DefectsandErrorsAreNOTtheSame

缺陷與錯(cuò)誤不是一回事Defectsareresults.Errorscauseresults缺陷是結(jié)果，錯(cuò)誤導(dǎo)致結(jié)果

Cause原因 Result結(jié)果 Errors錯(cuò)誤 Defects缺陷EverydayExamplesofErrorsandDefects

錯(cuò)誤和缺陷日常小例子Notsettingthetimeronyourtoasterproperly烤面包器的時(shí)間設(shè)置不恰當(dāng)Placingthe"original"inyourcopierfaceup在你的復(fù)印機(jī)面朝上放上“原稿”Runningoutofinkonyourdatecoder你的日期噴碼器沒有墨了Why?Burnttoast面包烤糊了Manyblankpages許多空白紙Nodatecodeontheproduct產(chǎn)品上沒有日期碼Defectsvs.Errors缺陷與錯(cuò)誤Definition定義Error:錯(cuò)誤Whenanyoftheconditionsnecessaryforsuccessfulprocessingarewrongorabsent.完善的處理/加工過程所必須的各種條件發(fā)生錯(cuò)誤或缺失Processingomissions

加工遺漏Processingerrors

加工錯(cuò)誤Errorinsettinguptheworkpiece

工件設(shè)置錯(cuò)誤Assemblyomissions(MissingParts)

裝配漏件InclusionofImproperpart/item

混件

Wrongworkpiece

工件搞錯(cuò)了Operationserrors

操作失誤Adjustment,measurement,dimensionalerrors

調(diào)整/測(cè)量尺寸失誤Errorsinequipmentmaintenanceorrepair

設(shè)備維護(hù)或修理錯(cuò)誤Errorinpreparationofblades,jigsortools

準(zhǔn)備刀夾具或工具失誤TenMostCommonErrors

10個(gè)常見錯(cuò)誤DamagedParts/Product

部件或產(chǎn)品損壞ReversedParts/Product部件或產(chǎn)品返工ForeignMatterPresent

夾雜MismatchedParts

部件不匹配MisalignedParts

錯(cuò)開的部件

Cannotbeassembled

不能裝配Inconsistenttestresults/testfailure

不一致的測(cè)試結(jié)果/測(cè)試失敗Badingmaterial

糟糕的來料Wrongmaterial/parts

錯(cuò)誤的物料/部件Wrongorinconsistentdimensions

錯(cuò)誤或不一致的尺寸Other...?

其他…..CommonDefectCategories

常見缺陷目錄...AndInConclusion小結(jié)Inanalyzingproblems,youmustunderstandthaterrorsanddefectsarenotthesame.

在分析問題的時(shí)候，你一定要知道錯(cuò)誤和缺陷不是一回事。SectionFour:第四部分RedFlagConditions紅旗條件Inevitabilityofhumanerror

錯(cuò)誤不可避免Whatareredflagconditions?

什么是紅旗條件？Exercise:identifyredflagconditions

課堂練習(xí)：識(shí)別紅旗條件HumanError-TwoImportantPremises

關(guān)于錯(cuò)誤的兩個(gè)前提Errorsareinevitable錯(cuò)誤不可避免Errorscanbeeliminatedthroughourcreativeefforts

通過我們的努力錯(cuò)誤可以被消除RedFlagConditions

紅旗條件Aconditioninthemanufacturingprocessthatcommonlyprovokeserrors制造流程中通常容易出錯(cuò)的情景條件RedFlagConditionsAdjustments（調(diào)整/校正）Tooling/toolingchanges（使用工具/加工切換）Dimensions/specifications/criticalconditions（尺寸/規(guī)格/關(guān)鍵條件）Manyparts/mixedparts（零部件混裝）Multiplesteps（步驟太多）Infrequentproduction（少量生產(chǎn)）Lackofaneffectivestandard（缺少有效的標(biāo)準(zhǔn)）Symmetry（對(duì)稱）Asymmetry（不對(duì)稱）RapidRepetition（快速復(fù)制）High/extremelyhighvolume（過大的數(shù)量/體積）Environmentalconditions（環(huán)境條件）Materials/processhandling（材料/工藝操作）Foreignmatter（外部因素）Poorlighting（差的照明）Housekeeping（勤務(wù)）RedFlag1Adjustments調(diào)整1位置不正RedFlag2Tooling/toolingchanges使用工具/加工切換2參考基準(zhǔn)上邊緣被用于定位參考基準(zhǔn)每個(gè)孔都是正確的深度嗎？RedFlag3Dimensions/Specifications/CriticalConditions尺寸/規(guī)格/關(guān)鍵條件3RedFlag4ManyParts/MixedParts零部件太多或混裝4你不曾遺忘過什么嗎？RedFlag5MultipleSteps步驟太多5我在哪一步？RedFlag6InfrequentProduction非常規(guī)產(chǎn)品6RedFlag7Lackofaneffectivestandard缺少有效標(biāo)準(zhǔn)7這個(gè)容器里應(yīng)放多少物料？RedFlag8Symmetry對(duì)稱性8RedFlag9Asymmetry非對(duì)稱性9RedFlag10RapidRepetition快速復(fù)制10RedFlag11HighVolume/ExtremelyHighVolume大容量/極大容量11RedFlag12EnvironmentalConditions環(huán)境條件12tTeamExercise（團(tuán)隊(duì)練習(xí)）Trytoidentifytheredflagconditionsinthefollowingexamples:

在下述示例中嘗試識(shí)別紅旗條件Example1（示例1）紐扣應(yīng)該均勻等距的縫制紐扣握持器視線看的角度紐扣Example2（示例2）流程還是儀表有錯(cuò)誤？Example3（示例3）在檢查的時(shí)無法看到已裝好的隱蔽部件Example4（示例4）A-D杠桿按鈕Example5（示例5）封閉的箱子–空的還是滿的？Example6（示例6）可能反向安裝裝配口電路板屏蔽箱對(duì)稱的安裝插片Example7（示例7）有刻痕無刻痕一體的部件...AndInConclusion（小結(jié)）Redflagconditionsarethosewhichcommonlyprovokeerrors.

紅旗條件指的是通常容易出錯(cuò)的作業(yè)方法或條件.SectionFive:第五部分DevelopMistakeProofingDevices開發(fā)防錯(cuò)裝置Definition:Areliablemethod定義：一種可靠的方法Theimprovementcycle

改善環(huán)Howtodevelopmistakeproofingdevices

如何開發(fā)防錯(cuò)裝置ThecyclebeginswithadherencetothecurrentproceduresTheImprovementCycle改善環(huán)Standardization標(biāo)準(zhǔn)化Analysis分析Improvement改善Westandardizethesuccessfulimprovementsandcontinuethecycle將成功的改善方案加以標(biāo)準(zhǔn)化，并持續(xù)該循環(huán)Weanalyzewhatwearedoingandtheresultswearegetting分析正在進(jìn)行的操作以及由此而產(chǎn)生的結(jié)果Baseduponouranalysis,wetakeimprovementaction基于分析結(jié)果，采取改善措施AdherenceDefinition:定義ReliableMethod可靠性方法Ismadeupofonlythoseelementswhich,whenfollowed,causeapredictableanddesirableresult,andwhennotfollowed,resultinapredictabledefectorwaste.該方法應(yīng)由一系列要素構(gòu)成，當(dāng)遵循這些要素時(shí)，將產(chǎn)生預(yù)期的可預(yù)測(cè)的結(jié)果，反之，將導(dǎo)致可預(yù)知的缺陷或浪費(fèi)。SevenStepstoMistakeProofing

差錯(cuò)預(yù)防七步驟Step1:步驟1

Identifyanddescribethedefect識(shí)別并描述缺陷Step2:步驟2

Determinewherethedefectisdiscoveredormade明確缺陷發(fā)生或發(fā)現(xiàn)之處Step3:步驟3 Detailthecurrentstandardprocedure詳細(xì)描述當(dāng)前的標(biāo)準(zhǔn)程序Step4:步驟4 Identifydeviationsfromstandards識(shí)別現(xiàn)有標(biāo)準(zhǔn)的變異Step5:步驟5 Identifytheredflagcondition(s)wherethedefectoccurs在缺陷發(fā)生之處，識(shí)別紅旗條件Step6步驟6 Identifythetypeofmistakeproofingdevicerequiredtopreventtheerrorordefect設(shè)計(jì)差錯(cuò)預(yù)防裝置以防止錯(cuò)誤或缺陷發(fā)生Step7:步驟7 Createdevice(s)andtestforeffectiveness對(duì)裝置有效性進(jìn)行測(cè)試MistakeProofing

DevelopmentChart差錯(cuò)預(yù)防裝置開發(fā)表Operation:_______________Product:___________________Date:_______________1A.DescribetheDefect:1B.ShowtheDefectRate:2.Identifythelocationatwhichthedefectis..Discovered:_________________________Made:_____________________________TimeDefects3.Detailthecurrentstandardprocedures/elementsoftheoperationwherethedefectismade(onestandard/elementpercard).4.Errorsordeviationsfromstandardswheredefectismade:5.Analyzethecauseforeacherror/deviation:Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?Why?RedFlagConditionsKeepAskingWhy?SourceErrorsIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdeaIdea6.Ideastoeliminateordetecttheerror.CheckMistakeProofingDeviceRequiredLevel1:EliminatecauseoferroratthesourceLevel2:DetecterrorasitismadeLevel3:Detectdefectbeforeitreachesnextoperation7.CreateMistakeProofingDeviceCurrentConditionMistakeProofingDeviceCurrentConditionMistakeProofingDeviceCosttoInstall:Remarks:TimetoInstall:Date:CosttoInstall:Remarks:TimetoInstall:Date:MistakeProofingImprovementStep1:Defect缺陷Step2:Location定位Step3:Operations操作Step4:Errors/Deviations

錯(cuò)誤/變異Step5:Analysis分析(5–Whys)Step6:ImprovementIdeas改進(jìn)建議Step7:ImplementedDevices完成裝置5Whys–Methodology“5個(gè)為什么”方法論Question“Why”agivensituationexistsorconditionhasoccurred.就現(xiàn)有狀態(tài)或問題發(fā)生條件詢問“為什么”Documenttheresponse.將答案記錄下來Evaluatetheresponse:“Why”didthishappenor“Why”isittrue.評(píng)估答案：為什么會(huì)發(fā)生/為什么它是正確的Documenttheresponse.將答案記錄下來Repeattheprocessuntiltherootcausefororiginalproblemisdetermined.重復(fù)該過程，知道最終確定問題發(fā)生的根源Step5步驟5

Analysis分析-

(WhyProblemIsOccurring)尋找問題發(fā)生的根源WHY?為什么5Whys–Example“5個(gè)為什么”示例Whydidthemachinestop?機(jī)器為什么停機(jī)？Becausethefuseblewduetoanoverload因?yàn)樨?fù)載過大保險(xiǎn)絲燒斷Whywasthereanoverload?為什么會(huì)出現(xiàn)負(fù)載過大？Becausethebearinglubricationwasinadequate.因?yàn)闈櫥怀浞諻hywasthebearinglubricationinadequate?為什么潤滑不充分？Becausethelubricationpumpwasn’tworking.因?yàn)闈櫥b置失效Whywasn’tthepumpworking?為什么該裝置失效？Becausethepumpaxlewaswornout.因?yàn)檠b置軸承出現(xiàn)磨損Whywasitwornout?為什么出現(xiàn)磨損？Becausesludgegotonit.因?yàn)樗樾几街谏厦鍿tep5步驟5

Analysis分析-

(WhyProblemIsOccurring)尋找問題發(fā)生的根源AnalyzethefollowingproblemandconstructaFiveWhysDiagram:分析下列問題并制作“5個(gè)為什么”表Youjustfinishedaprojectandwantedtomake5copiesof20pages,collatedandstapled.Yougotothecopierandputtheoriginalinthetrayontop.Yousetthecopierfor20copies,collatedandstapledandhitthe“on”button.Nocopiesaremade.Themachineisoutofpaper.你剛剛完成一個(gè)項(xiàng)目報(bào)告20頁，希望復(fù)制5份并校對(duì)裝訂。你走向打印機(jī)并將初始文稿放在打印口，將機(jī)器設(shè)置為復(fù)印20份并校對(duì)裝訂，同時(shí)按下了開始按鈕。文稿沒有被復(fù)印。機(jī)器沒紙了。Yourcauses(theanswerstothefivewhys)maybealittledifferentfromtheanswersheet,butyouwillrecognizethecauses.您的答案可能與答題紙顯示稍有不同，不管怎樣，您終究能找到根本原因。5WhyExercise“5個(gè)為什么”練習(xí)5WhyTargetForm“5個(gè)為什么”目標(biāo)表為什么Why?Problem:問題Cause:原因Cause:原因Cause:原因Cause:原因RootCause:根本原因?yàn)槭裁碬hy?為什么Why?為什么Why?為什么Why?UsingCardsontheMistake

ProofingChart在差錯(cuò)預(yù)防表格中使用卡片StandardElementsoftheOperation(Step3)UsePinkCardImprovementIdeas(Step6)UseBlueCardErrors/Causes(Steps4-5)UseYellowCard操作的標(biāo)準(zhǔn)要素（步驟3）使用粉紅色卡片錯(cuò)誤/原因（步驟4-5）使用黃色卡片改進(jìn)建議（步驟6）使用藍(lán)色卡片CardwritingGuidelines卡片填寫指南Writeoneelement,cause,orideapercard

每一卡片填寫一個(gè)要素、原因或建議Bespecificandcomplete

內(nèi)容明確且完整Useafullsentence,notaphraseoraword

使用整句，而非短語或單詞Initialanddatecards

注明卡片的初始狀態(tài)及日期Writesootherscanread

使其他人易于閱讀Followcolorcodeonchart

遵循圖表的顏色編碼...AndInConclusion總結(jié)Mistakeproofinghelpsensureadherencetoreliablemethods.差錯(cuò)預(yù)防有助于保證可靠性方法的執(zhí)行。Thefirstfivestepsofthemistakeproofingprocessareforanalysis.

差錯(cuò)預(yù)防過程的前五個(gè)步驟為分析階段。SectionSix:第六部分ImprovementGuidelines&Examples改進(jìn)方案&示例Functionofmistakeproofingdevices差錯(cuò)預(yù)防裝置的功用Typesofdevices

裝置的種類Levelsofintervention

干涉級(jí)別Examplesandredesigns

示例及重新設(shè)計(jì)FunctionofMistake

ProofingDevices差錯(cuò)預(yù)防裝置的功用Mistakeproofingdevicesaresimpleandinexpensive.Theyareused:差錯(cuò)預(yù)防裝置應(yīng)該簡單且便宜。它們可以用來：Topreventerrorsfromhappening防止錯(cuò)誤的發(fā)生Todetecterrorsthathaveoccurred偵測(cè)已發(fā)生的錯(cuò)誤Todetectdefectsthathaveoccurred偵測(cè)已發(fā)生的缺陷FastFeedback快速反饋100%Inspection100%檢驗(yàn)MistakeProofing差錯(cuò)預(yù)防

3LevelsofPrevention預(yù)防的三個(gè)層次Inexpensive價(jià)格便宜Focused關(guān)注點(diǎn)突出EasytoImplement易于執(zhí)行TeamBased以團(tuán)隊(duì)為基礎(chǔ)Level1第一層EliminatetheError消除錯(cuò)誤Level2第二層次DetecttheError偵測(cè)錯(cuò)誤Level3第三層次DetecttheDefect偵測(cè)缺陷1.Guide/reference/interferencerodorpin導(dǎo)向/參考/干涉銷2.Template模板3.Limitswitch/microswitch限位開關(guān)/微動(dòng)開關(guān)4.Counter計(jì)數(shù)器5.Odd-part-outmethod顯示剩余零件的方法6.Sequencerestriction序列限制7.Standardizeandsolve標(biāo)準(zhǔn)化和解決方案8.Criticalconditionindicator關(guān)鍵條件指示器9.Detectdeliverychute探測(cè)遞送滑道10.Stopper/gate停止器/門11.Sensor傳感器12.Mistakeproofyourmistakeproofingdevice:對(duì)你的防錯(cuò)裝置進(jìn)行防錯(cuò)設(shè)計(jì)Eliminatethecondition消除問題發(fā)生的條件Redesignforsymmetry對(duì)稱性設(shè)計(jì)Redesignforasymmetry非對(duì)稱性設(shè)計(jì)TypesofMistakeProofingDevices

差錯(cuò)預(yù)防裝置的種類MPDevice1:差錯(cuò)預(yù)防裝置1

Guide/Reference/InterferenceRods

導(dǎo)向/參考/干涉銷MPDevice2:差錯(cuò)預(yù)防裝置2

Template模板MPDevice3:差錯(cuò)預(yù)防裝置3

LimitorMicroswitch限位開關(guān)/微動(dòng)開關(guān)DepthMPDevice4:差錯(cuò)預(yù)防裝置4

Counter計(jì)數(shù)器MPDevice5:差錯(cuò)預(yù)防裝置5

Odd-Part-OutMethod顯示剩余零件的方法MPDevice6:差錯(cuò)預(yù)防裝置6

SequenceRestriction序列限制MPDevice7:差錯(cuò)預(yù)防裝置7

StandardizeandSolve標(biāo)準(zhǔn)化及解決方案MPDevice8:差錯(cuò)預(yù)防裝置8

CriticalConditionDetector關(guān)鍵條件指示器TypesofElementDetectors

探測(cè)器的種類Fluidelementdetectors流體探測(cè)器Pressurechangedetectors壓力探測(cè)器Temperaturechangedetectors溫度探測(cè)器Currentfluctuationdetectors波動(dòng)探測(cè)器MPDevice9:差錯(cuò)預(yù)防裝置9

Delivery(Detect)Chute遞送（探測(cè)）滑道MPDevice10:差錯(cuò)預(yù)防裝置10

Stopper/Gate停止器/門MPDevice11:差錯(cuò)預(yù)防裝置11

Sensor傳感器Beam&Fiber光束&光纖Area面積Positioning配置Displacement位移MetalPassage金屬通路ColorMarking顏色標(biāo)識(shí)Vibration振動(dòng)TypesofSensors傳感器種類MPDevice12:差錯(cuò)預(yù)防裝置12

MistakeProofYourMistakeProofingDevice

對(duì)你的防錯(cuò)裝置進(jìn)行防錯(cuò)設(shè)計(jì)OtherPreventionTechniques其他預(yù)防技術(shù)Eliminate-ConditionMethod消除問題發(fā)生的條件OtherPreventionTechniques其他預(yù)防技術(shù)

RedesignforSymmetry對(duì)稱性設(shè)計(jì)OtherPreventionTechniques其他預(yù)防技術(shù)

RedesignforAsymmetry非對(duì)稱性設(shè)計(jì)DesignandCreateImprovements

設(shè)計(jì)并進(jìn)行改善Step6步驟6

Identifythetypeofmistakeproofingdevicesrequired

識(shí)別所需的差錯(cuò)預(yù)防裝置的類型Step7步驟7 Createappropriatedevicesandtesttheireffectiveness

制作適當(dāng)裝置并測(cè)試其有效性MistakeProofingReportForm

差錯(cuò)預(yù)防報(bào)告格式Team:團(tuán)隊(duì)__________________________Plant/Location:工廠/地域____________________Date:日期_______________________CurrentCondition:當(dāng)前狀態(tài)ImprovementUsingMistakeProofing:使用防錯(cuò)裝置后的改進(jìn)?Defect:缺陷________________________?SourceError:源頭錯(cuò)誤_______________?CosttoInstall:安裝成本______________?TimetoInstall:安裝時(shí)間____________?Remarks:備注?Operation:作業(yè)________________________?RedFlat:紅旗________________MistakeProofingDevice:差錯(cuò)預(yù)防裝置________________________________?LevelOne/EliminateAtSource:第一層次/從源頭消除______________________?LevelTwo/DetectatSource:第二層次/在源頭探測(cè)______________________?LevelThree/DetectBeforeNextOperation:第三層次/在下一操作前探測(cè)______...AndInConclusion總結(jié)Todevelopeffectivemistakeproofingsolutions,befamiliarwiththebasicdevicetypesandthethreelevelsofmistakeproofingprevention.制訂有效的差錯(cuò)預(yù)防方案，需要熟悉基本的裝置類型以及差錯(cuò)預(yù)防的三個(gè)層次。5WhyTargetForm“5個(gè)為什么”目標(biāo)表Why?為什么Problem:Nocopiesarebeingmade問題：文稿沒有被復(fù)印Why?為什么Cause:Thereisnopaper原因：機(jī)器沒紙了Cause:Nopapersupplynexttothecopier原因：紙張沒有及時(shí)補(bǔ)充Cause:Nopaperinthesupplycupboardforthisdepartment原因：該部門中的物料柜中沒有紙。Cause:Someonedidn’torderpaper原因：沒有人訂購紙張。RootCause:Theremaybeanumberofreasonsatthispoint,someofwhichmayinclude:thereisnobudgetforofficesupplies,someoneforgottoorderpaper,nooneisassignedtoorderpaper,ourdepartmentusedmorepaperthannormalthismonthsoweranoutbeforeourregularorderwasreceived,etc.根本原因：就該問題而言，可能有若干種原因，其中包括：辦公材料的供給沒有預(yù)算、有人忘記訂購紙張、訂購紙張的任務(wù)沒有委派到個(gè)人、該部門當(dāng)月所用紙張超過正常水平，因此在正常訂購送達(dá)之前出現(xiàn)缺紙、等等。Why?為什么Why?為什么Why?為什么案例練習(xí)Title:O-RingRemoval題目：O形密封圈的移除WhenremovingoldO-Ringsduringthedisassemblyprocessitisveryeasytodamagethebrassspoolvalves.Wedevelopedasimplemachinethatwouldcuttheo-ringwithoutdamageandalsospeeduptheprocess.Previousmethodsincludedsoakingincarburetorcleaner(hazardousmaterial)anddryremoval.Dryremovalcausesthemostdamagebutthecarburetorcleanerissmellyandrequiresrubberglovestohandleparts.在拆卸環(huán)節(jié)，當(dāng)我們移除舊O形密封圈時(shí)，很容易損壞其中的短管閥。我們制作了一個(gè)簡單的設(shè)備，使其能夠在不發(fā)生損壞的情況下切開O形圈，并能夠提高該過程的速度。在之前的方法中，需要先吸收化油器清潔劑（有害物質(zhì)），并采用干法去除。干法去除是造成損壞的最大原因，同時(shí)，因?yàn)榛推髑鍧崉?huì)產(chǎn)生異味，在處理過程中需要配帶橡膠手套。Simplysetspoolvalveinholder,closetoggleclamp,pressblackbuttonando-ringsarecut!只需簡單的將短管閥嵌入支架，合上肘節(jié)式價(jià)錢，按下黑色按鈕，O形密封圈將會(huì)被切開！Title:MistakeProofing:AcidTank-SpringLoadedWaterFillValve題目：差錯(cuò)預(yù)防：酸液槽—彈力進(jìn)水閥Theacidtankisheatedandconstantlyevaporateswater.Thetankmustnotbeoverfilledortheacidrunsoverthetopofthetank.Wehadanautomaticfillvalvebutitwasnot100%dependable.Whenwehadamanualvalve,theworkerwouldturniton,getdistracted,walkawayandthenthetankwouldoverflow.Nowwehaveaspringloadedvalvethatrequirestheworkertoholditopeninorderforthewatertoflow.Whentheworkerletsgo,thevalveshutsoff.Nomoreoverflowproblem.酸液槽需要加熱并持續(xù)不斷的蒸發(fā)水分，同時(shí)需要嚴(yán)防酸液溢出。我們已經(jīng)有了一個(gè)自動(dòng)進(jìn)水閥，但是它并非100%可靠。如果我們安裝手動(dòng)閥門的話，操作者若在開啟閥門之后走開的話，將有可能造成液體溢出?，F(xiàn)在我們裝上彈力進(jìn)水閥之后，操作者需要握住閥門以注入液體。當(dāng)操作者離開時(shí)，閥門將自動(dòng)關(guān)閉，從而避免了液體溢出的問題。案例練習(xí)Title:Mistakeproofing:Fixtureimprovesquality,safety&efficiency

題目：差錯(cuò)預(yù)防：工裝夾具能夠提高質(zhì)量、安全性&效率OldMethod:(Nofixture:Usevise&holdrollpinwithfingers)Assemblyoperation:assemblerollpinintofemalerodend.Itwasalwaysdifficultinsertrollpinhalfwayasrequired.原方法：（沒有工裝：使用手指拿握銷輥）裝配作業(yè)：將銷輥裝到搖桿頭。將銷輥按要求插入一半非常困難。Unsafeoperation非安全作業(yè)&poorquality質(zhì)量低下Fixtureholdsrodend&operatorcanpeenrollpinwithpunch&holdexactdimension用工裝固定搖桿頭&操作者可用錘子敲擊銷輥&保證精確角度Theoperatorafterusingthenofixtureandvisemethod,hadanideaofaneasierandsaferwayofperformingthisassembly.Withhisideaandthehelpofatoolmaker,anewassemblyfixturewasimplemented.Thisideanotonlyimprovedqualityofthefinalassemblyofthissubassemblybutmadethisasaferoperationandimprovedtheefficiencyofthisoperation,byeliminatingnon-valueaddedtasks,costsavingo