MISTAKE_PROOF中文.ppt

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,*,MISTAKE-PROOFING,防,误措施,ACE Elements,QCPC,Root Cause/,Corrective,Action,Passport,Process,Management,Standard,Work,Mistake,Proofing,Market,Feedback,Analysis,6S,Quality,Clinic Activity,TPM,ACE,内容,质量,诊断程序,图表,根本,原因,修正,行动,设计,开发通行证,程序,管理,标榜,化作业,防,误措施,市场,反馈,分析,6S,质量,诊断,行动,全面,生产性,维护,ACE Elements,Engineering New Products,Processes&Systems,Passport,-,Systematic method for review/approval of new designs,Standard Method,Process Management-Means to identify&map key business processes,Standard Work,-,Repeatable processes that are effective and efficient,Quality Improvement Methods,QCPC,-Simple tool to identify problems and inefficiencies(,turnbacks,),MFA,-,Data summaries that display how components perform in field,Root Cause,-,Method to drive to the true source of problems,Standard Environment,New 6S,-,Workplace organization and visual control,Total Productive Maintenance,-,Continuously improving equipment effectiveness/availability,Mistake-Proof,-Creation of devices that ensure a task is always done correctly,ACE,内容,开发新产品、程序和系统,设计,开发通行证,-,检查/批准,新,设计的系统方法,标准,方法,程序,管理,识别,并展示重要商业程序的方法,标准,化作业,-可,重复的有效程序,质量,改进方法,质量,诊断程序图表,-,识别问题和低效率（返工）的简单工具,市场,反馈分析,-,展示组件是怎样工作的数据摘要,根本,原因,-,发现问题的真正来源的方法,标准,环境,新,6S,-,工作,场地组织和直观控制,全面,生产性维护,-,不断,地改善设备的有效性和可用性,防,误措施,-,确保,任务总能正确完成的设备的措施,Increase,profitability,by eliminating inadvertent mistakes,消除,无谓的错误可增加,利润率,Increase,productivity,by reducing wasted time,减少,浪费的时间可提高,生产力,Improve,customer satisfaction,and,quality,by eliminating escapes,消除,逃脱可提高,客户满意度,和,质量,Increase,reliability,by continuously improving products,services or processes,不断,改进产品、服务或程序可提高,信誉,Benefits of Mistake-Proofing,防,误措施的好处,They are not the same thing!,Mistakes,Cause,Defects.,他们,是不同的！,错误导致过失,Mistakes vs.Defects,错误vs,过失,Mistake,错误,Defect,过,失,Pumping diesel fuel into your gas tank.,将,柴油加入汽油箱,Running a red light.,撞,红灯,Forgetting to unplug your iron.,忘,记拔掉电熨斗的插头,Placing the“original”in your copier feeder“face down”.,将,原件放进了复印机的进纸处并正面冲下,or,Misunderstanding requirements,误解,了要求,Skipping a process step or tasks,漏,掉了一个工作步骤,Performing process steps incorrectly or in the wrong order,未,正确地或以错误地顺序执行程序步骤,Contamination,污染,Most Common Mistakes,最,常见的错误,Leaving out a part or a piece of information,漏,掉了一个零件或一条信息,Adjustment and measurement mistakes,调节,和测量错误,Timing mistakes,定时错误,Using the wrong parttool or information,使用,了错误的零件、工具或信息,Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is,always,done correctly.,防,误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。,Mistake-Proofing,防,误措施,It removes uncertainty from the situations where errors are most likely to occur,such as:,它,去除了最可能发生错误的情形中的不确定性，如：,Repetitive tasks,重复,性的任务,Complex instructions,复杂,的说明书,Calculations/Adjustments,计算,/,调节,Look-alike parts,相似,的零件,Why do we do Mistake Proofing?,为,什么我们要采用防误措施？,To prevent,turnbacks,and,customer escapes,from recurring,since the cost to fix a problem increases rapidly the later it is found:,为防止缺陷和客户逃脱情况再次发生，因为问题发现得越晚所花的费用就会迅速增加：,If a defect occurs here,如果,在这儿发生过失,and its found here,并,在这儿被发现，,it costs:,就,要花费：,Rework,repair,scrap and escapes cost UTC$148 million per year.,Warranty expenses cost us another$600 million per year.,The cost of lost customer loyalty due to escapes is immeasurable.,返,工、修理、废弃和逃脱每年要花掉,UTC1.48,亿。,保修,费用每年花掉我们另外6亿。,由于逃脱而丧失了客户的信任的损失则不可计算。,Design,设计,DevelopProcess,进行,加工,Op 2,Customer,客户,Op 1,Op 1,Op 2,$1,$10,$100,$1,000,$10,000,Mistake-Proof,防,误措施,the Design,设计,Redesign the product,重新,设计产品,Eliminate the mistake condition,消除,犯错误的条件,Redesign for symmetry or asymmetry,重新,进行对称或不对称设计,Change the materials,改变,材料,Change component type,characteristics or supplier,改变,组件的类型、特征或供应商,2 Approaches to Mistake Proofing,预防,错误的2个途径,Mistake-Proof,防误措施,the Process,加工,Change or add tooling,改变,或增添工具,Change process steps,改变,加工步骤,Add use of checklists,templates or gages,增,加使用清单、模板或测量仪,Implement control charts,执,行控制图表,Process Description:Making a pot of coffee,程序,描述：泡一壶咖啡,Example of Mistake-Proofing the Design,防,误措施范例 设计,Before Improvement:,改进,前：,Water needed to be measured for each pot of coffee often resulting in coffee that was too weak or too strong,泡前每壶咖啡的水量都要测量常常导致咖啡过淡或过浓。,Process Description:Making a pot of coffee,程序,描述：泡一壶咖啡,Example of Mistake-Proofing the Design,防,误措施范例 设计,After Improvement:,改进,后：,Coffee maker was redesigned to measure and add the precise amount of water from a water bottle,重新,设计咖啡机以使每次从水瓶中加入的水的量都一样多,Process Description:A label is pasted into a recess in a molded chassis,程序,描述：将标签贴在底盘的凹槽内,Example of Mistake-Proofing the Design,防,误措施范例 设计,Before Improvement:,改进,前：,The recess and the label were both rectangular.The label could be glued in upside-down.,凹槽和标签都是长方形。标签可能会贴反。,Recess in chassis,底盘的凹槽,Label,标,签,Model T6,AC 110V,10 W,After Improvement:,改进,后：,A notch was made in the corner of the label,and in the recess of the chassis.Incorrect mounting is completely eliminated.,在,标签和凹槽的一角做一个切口。就能完全防止错误发生。,Recess in chassis,底盘的凹槽,Label,标,签,Model T6,AC 110V,10 W,Example of Mistake-Proofing the Design,防,误措施范例 设计,Process Description:Install slides into a slide projector,程序,描述：将幻灯片装入幻灯机中,Before Improvement:,改进,前：,Are some slides upside down?,有,一些幻灯片装反了吗？,After Improvement:,改进,后：,Top edge of each slide marked with a,red dot.,每,张幻灯片的上边都有一,红点,。,Example of Mistake-Proofing the Design,防,误措施范例 设计,Process Description:,Torquing,a number of bolts recessed deep in a cavity.,程序,描述：将大量螺栓拧进空腔深处的凹槽内,Before Improvement:,改进,前：,The socket extension required to reach the bolts caused nicks and scratches in the painted surfaces that it contacted during assembly,.,在操作的过程中，用来拧螺栓的拧杆柄会对油漆表面造成刮伤。,After Improvement:,改进,后：,A rubber hose was installed over the socket extension and was specified on the work instructions.,一,个橡皮管被装在拧杆柄上并在工作说明书上有详细说明。,Mistake-Proofing is a way of using,wisdom and ingenuity,to create,devices,that ensure a task is always done correctly.,防,误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的,设备,的方法。,Mistake-Proofing isnt,Words!,防误措施不是,文字！,Word,“Solution”,文字,“,解决方法”,Problem,:The“One Day“employee badge form asks for badge#and clock#.Employees often write their clock#in the badge#spot.,问题,：“,一日”雇员的证件表格要求填写证件号和钟点号。雇员常将钟点号填在证件号的位置。,Badge#,证件,号,Clock#,钟点,号,(filled out by Emergency Services),（由,紧急服务部填写）,(filled out by employee),（由,雇员填写）,True Mistake-Proofing,真正,的防误措施,1 Day Badge#,1,日,证件号,All gray areas filled,out by Emergency,Services,所,有灰色区域由紧急服务部填写,Employee Clock#,雇员钟点号,All yellow areas,filled out by,Employee,所,有黄色区域由雇员填写,Guide pins or interference pins,向,导图钉或干涉图钉,Templates,模,板,Part kits using shadowboxing,使用,能防止错误的零件包,Limit switches,限制,阀,Most Common Types of Mistake-Proof Devices,最,常见的防误设备,Counters,计算,器,Alarms,闹钟,Weights and measures,称重秤和测量仪,Checklists,清单,Control charts,控制,图表,Mistake-Proofing Process Changes,防,误码程序的改变,Improve the process!,改进,程序！,Simplify,简单,化,Reduce steps,parts,forms,data on forms,number of process steps,etc.,减少,步骤、零件、表格、表格上的数据、加工步骤的数量等。,Consolidate/Co-Locate,巩固,/,共用,Bring operations closer together,reduce work-in-process(WIP),使,操作变得更紧凑，减少过程工作（,WIP）,Standardize,标准,化,Make the process visual,使,程序可见,Move responsibility and authority down in the organization,将,责任和权利下放给组织,Try-Storming(vs.Brainstorming),尝,试风暴（对头脑风暴）,Involve the right people,让,合适的人参与,Walk the process and get the facts,检验程序并获得事实,Dont just sit and think about solutions.TRY THEM!,不,要只是坐在那儿想解决问题的方法,去,尝试！,Creating Mistake Proofing,创建,防误措施,The“Nasty Test”(vs.the“Solution”),“,恶,心的试验,”（,对“,解决方法”,）,When you think youve got the best solution TRY TO MAKE IT FAIL!,当,你认为你已找到最佳解决方法时,试,着去让它失败,Involve all users,让,所有使用者参与,Mistake-proof devices must be 100%effective at dealing with a particular mistake,在处理特殊错误时,防,误设备必须100%有效,If not,they will be ignored,如果,不能，就应放弃,Ensure the mistake-proof doesnt create another problem,确保,防误措施不会引起其它问题,Test Mistake Proofing with the“Nasty Test”,用“,恶心的试验”来验证防误措施,Formally,as part of the QCPC/MFA Process,形式,上的，作为,QCPC/MFA,程序中一部分,When do you do Mistake-Proofing,何,时采取防误措施,Notice mistake as it happens,当错误发生时要留意,Develop a simple fix to prevent it from recurring.,开发出一种简单方法来防止它再发生,Implement the simple fix into the standard process,在,标准程序中运用这种简单方法,Use,QCPC,to collect,Turnback,data,使,用,QCPC,来收集缺陷数据,Use,Pareto Analysis,to Identify top,turnbacks,用,Pareto,分析,来识别最高缺陷率,Perform,Root Cause Analysis,to identify Root Cause,用,根本原因分析,来识别根本原因,Develop&implement,Mistake-Proofs,to prevent recurrence.,开发并执行,防误措施,来防止错误的再发生,2)Real-time,whenever you notice a mist,ae,occurring,or,the potential for a mistake,实,时的，无论何时你发现一个错误或有出错的可能性,There are 3 Levels of Mistake-Proofing based on effectiveness and speed:,防误措施,有,三个基于有效性和速度的等级：,Level III:Detection,等级三：发现,Level II:Alert,等级二：警告,Level I:Prevention,等级一：防止,Three Levels of Mistake-Proofing,防,误措施的三个等级,Level III,Detect:Allows you to detect your Mistake after it has occurred.(1 point),等级三，发现：在已经发生之后发现错误,Checklists,清单,Computer beeps,电脑,提醒,Manually activated Spell Check,手,工拼写检查,Level II,Alert:Alerts you as the Mistake is happening.(2 points),等级,二，警告：当错误正在发生时提醒你,Sensors,alarms,control charts,传感器、闹钟、控制图表,Counters,计算,器,Automatic Spell Check,自动,拼写检查,Level I,Prevent:Prevents you from making the Mistake.(3 points),等级,三，防止：防止你犯错误,Eliminating the mistake condition(changing the design),消除,犯错条件,Automation,自动,控制,Spelling“Auto-corrector”,拼写,“,自动更正器”,Three Levels of Mistake-Proofing,防,误措施的三个等级,Mistake Proofing Qualifying Level Items,防,误措施合格水平内容,The following 2 items are required to achieve the ACE Qualifying level for Mistake Proofing,要,取得,ACE,的防误措施合格资格必须完成以下两项内容,ACE element awareness training for all employees.,针对,所有员工的,ACE,内容认知培训,2.Document and post on the,ACE Display Board at least,1 example of Mistake Proofing,Implemented(any level.),至少记录,并张贴一个已完成的防误措施,（任何等级）在,ACE,展示板上,Summary,总,结,Mistakes are not inevitable.,错误,不是不可避免的。,A Mistake-Proof is a creative device that prevents a mistake from happening.It should be:,防,误措施是一项有创造性的设备能防止错误发生。它应该是：,Simple,简单,的,Inexpensive,不,昂贵的,Reliable at preventing defects or giving prompt feedback.,在,防止错误或给出提示反馈时可靠的。,Mistake Proofing is critical to process improvement.,防,误措施对程序改进很重要。,Necessary to achieve QCPC,turnback,reduction goals.,对,达到,QCPC,减少缺陷的目标是必要的,Mistake-Proofing enhances our work environment by making it easier to do our jobs well.,防,误措施通过使我们的工作更容易作好来改善我们的工作环境,