红带安全评审.ppt

D D MM A A D D V V2024/4/21 周日可编辑1Introduction to the Safety Review 安全评审介绍Design Module设计模块RevisionRevision修订本修订本 5.1:8-19-065.1:8-19-06D D MM A A D D V V8/19/2006 DesignRevision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company24.0 设计设计方案方案目标目标主要活动主要活动会用到的工具和技术会用到的工具和技术关键交付文件关键交付文件确认/改善功能转换模型选择设计方案确定方案对比结果完成设计阶段的失效模式和影响分析完成可靠性试验制定验证计划设计产品/流程实施蒙特卡洛分析确定公差评审优先设计,批准对比方案.通过设计和关键客户要求,确定/记录关键质量特性.在设计参数中评估关键客户要求的可变性.确定潜在的失效模式.实施公差分析功能转换模型确认/改善完成制定分数卡量化方案对比确定公差设计阶段的失效模式和影响分析设计分析详细设计验证“试验”计划1.0 1.0 定义定义 2.0 2.0 测量测量3.03.0分析分析分析分析 4.0 4.0 设计设计 5.05.0 验证验证Items in tan are also DMAIC tasks,and are not specifically re-taught in the DFSS program8/19/2006 DesignRevision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company2D D MM A A D D V V2024/4/21 周日可编辑34.0 Design SolutionObjectiveMain ActivitiesPotential Tools and TechniquesKey DeliverablesValidate/refine Transfer Function modelsSelect from among candidate design alternativesIdentify trade-offsComplete Design FMEAsComplete reliability testingCreate verification planDesign product/processPerform Monte Carlo analysesSet tolerancesReview priorities,approve trade-offs as neededIdentify/document CTQ Flow-Down from customer CCRs through design parametersAssess sensitivities of CCRs to variability in design parametersIdentify potential failure modesPerform tolerance analysisValidated/refined Transfer FunctionsScorecards generatedTrade-offs quantifiedTolerances setDesign FMEADesign AnalysisDetailed designVerification“Test”Plan1.0 1.0 DefineDefine2.0 2.0 MeasureMeasure3.03.0AnalyzeAnalyze 4.0 4.0 DesignDesign 5.05.0 VerifyVerify Items in tan are also DMAIC tasks,and are not specifically re-taught in the DFSS programD D MM A A D D V V2024/4/21 周日可编辑4Types of Reviews评审类型qqThe Technical ReviewsThe Technical Reviews技术评审技术评审qqThe Manufacturing ReviewThe Manufacturing Review生产评生产评审审qqService ReviewsService Reviews服务评审服务评审qqSafety&Legal ReviewsSafety&Legal Reviews安全和法规安全和法规评审评审qqThe Tollgate ReviewsThe Tollgate Reviews阶段评审阶段评审These reviews need to be evaluated,scored and added to the Project Scorecard.Traffic lighting should be present on the Scorecard to represent the schedule and the risk to the Management Team.这些评审需要进一步的评估,打分,添加到项目分数卡上.“交通指示灯”应该显示在分数卡上,为管理团队显示出进度和风险.Design Issues设计问题Process FMEA流程失效模式影响分析ProblemsDeviations问题差异Tollgate Reviews阶段评审D D MM A A D D V V2024/4/21 周日可编辑5Key Items for the Safety ReviewKey Items for the Safety Review安全评审的关键项目安全评审的关键项目qRegulatory informationRegulatory information行业法规行业法规qProduct Safety GuidelinesProduct Safety Guidelines产品安全指导文产品安全指导文件件qErgonomicsErgonomics人体工程学人体工程学qProactive ManagementProactive Management主动管理主动管理D D MM A A D D V V2024/4/21 周日可编辑6Performing a Safety Review实行安全评审qqPerforming a safety review Performing a safety review during the design phaseduring the design phase results in the best results in the best utilization of resources(time&money).utilization of resources(time&money).在设计阶段执行安全评审是利用资源在设计阶段执行安全评审是利用资源(时时间和金钱间和金钱)的最好时机的最好时机.qqThe outcome of the Safety review is in the many project stages and The outcome of the Safety review is in the many project stages and reviews to have the greatest impact.reviews to have the greatest impact.安全评审的结果是在项目的不同阶段有最大安全评审的结果是在项目的不同阶段有最大的影响的影响.qqThe project engineer is responsible for providing his customers,the The project engineer is responsible for providing his customers,the employee&end user,with equipment,processes and tools which allow employee&end user,with equipment,processes and tools which allow them to build and utilize the equipment safely.them to build and utilize the equipment safely.项目工程师负责向客户项目工程师负责向客户,工人工人,终终端用户提供设备端用户提供设备,流程和工具流程和工具,并且能够安全的操作这些设备并且能够安全的操作这些设备.qqThe graph on the next slide shows The graph on the next slide shows the cost of the cost of waitingwaiting to consider to consider ergonomics until the equipment ergonomics until the equipment is delivered at the facility is delivered at the facility increases the cost.increases the cost.下页的图标说明了下页的图标说明了:指导设备到达工厂才开始考虑指导设备到达工厂才开始考虑 人性化因素而造成的成本人性化因素而造成的成本,是成本增加是成本增加.D D MM A A D D V V2024/4/21 周日可编辑7Costs Of Deferring The Consideration Of Ergonomics In An Costs Of Deferring The Consideration Of Ergonomics In An Engineering Project*Engineering Project*在工程项目中在工程项目中,推迟人性化因素考虑而造成的成本推迟人性化因素考虑而造成的成本*Dave Alexander&Associates-3/22/19941/2%2-3%5%10-20%Concept方案阶段Blue Print蓝图阶段 Build Stage制造阶段Do Nothing什么都不做(Change during build 制造阶段整改)(Correct later 之后改正)Stage of Project项目阶段D D MM A A D D V V2024/4/21 周日可编辑8qqA list of items typically A list of items typically considered during a safety considered during a safety review are shown to the review are shown to the right.right.安全评审应该考虑的项目安全评审应该考虑的项目列在右侧：列在右侧：qqTools such as checklists,Tools such as checklists,Ergonomic Job Ergonomic Job Measurement System Measurement System(EJMS)and Safety(EJMS)and Safety Engineering Guide will be Engineering Guide will be available in the future for available in the future for analysis during the design analysis during the design phase.phase.检查列表检查列表,符合人体工程符合人体工程学的测量系统以及安全工程指学的测量系统以及安全工程指导等工具会在将来的设计阶段导等工具会在将来的设计阶段分析中用到分析中用到.Lockout/Tag out&ElectricalLockout/Tag out&Electrical防防护警告标示护警告标示,电气电气Machine GuardingMachine Guarding机器安全防护机器安全防护Fall PreventionFall Prevention坠跌预防坠跌预防Confined SpacesConfined Spaces有限空间有限空间ErgonomicsErgonomics人体工程学人体工程学NoiseNoise噪音噪音Fire PreventionFire Prevention防火防火Hazardous Hazardous Chemicals/Industrial HygieneChemicals/Industrial Hygiene危危险化学品和工业卫生险化学品和工业卫生Controls&DisplaysControls&Displays控制与展示控制与展示Design for maintenance&Design for maintenance&repairrepair维护和修理设计维护和修理设计Performing a Safety Review实行安全评审D D MM A A D D V V2024/4/21 周日可编辑9Safety Analysis for an OperationSafety Analysis for an Operation操作的安全分析操作的安全分析操作的安全分析操作的安全分析qqAn operation,the process of assembling a product or the An operation,the process of assembling a product or the use of an end product,can also be evaluated.This is most use of an end product,can also be evaluated.This is most commonly done using a process known as Job Safety commonly done using a process known as Job Safety Analysis(JSA).Analysis(JSA).操作操作,装配产品流程或者使用终端产品装配产品流程或者使用终端产品,都是可以评都是可以评估的估的.最广泛应用的程序是工作安全分析最广泛应用的程序是工作安全分析.qqThe following are considered during a JSA:The following are considered during a JSA:工作安全分析考虑工作安全分析考虑的因素的因素:mmPast injuries or near misses.Past injuries or near misses.以往的事故或者以往的事故或者“有惊无险有惊无险”的事故的事故.mmBrainstorming of hazards for critical task involved with the Brainstorming of hazards for critical task involved with the assembly or use of the equipment.Determination as how to assembly or use of the equipment.Determination as how to best eliminate or control each hazard.best eliminate or control each hazard.对关键工作对关键工作,装配或者使用装配或者使用设备进行设备进行”头脑风暴头脑风暴”,列出容易出现问题的地方列出容易出现问题的地方,并确定如何最好的并确定如何最好的消除或控制这些问题消除或控制这些问题.mmEvaluation of possible unintended uses of the equipment.Evaluation of possible unintended uses of the equipment.评估评估设备使用中可能引起的意外发生的情况设备使用中可能引起的意外发生的情况.D D MM A A D D V V2024/4/21 周日可编辑10Back to the Catapult Case StudyBack to the Catapult Case Study投石器案例学习投石器案例学习OverviewOverview概述概述The catapult(the piece of machinery that your project will be focused on)produces shots of various lengths depending on several factors including:以下几个因素决定投石器会投射出不同的距离：Pull back angle回拉的角度 Ball used球的选择 Release technique发射技巧 Bolt positions螺栓的位置In truth customers demand both shots of maximum length and shots whose length they specify to+/-15.0+/-15.0 cm.Improve your ability to meet customer demand for long shots as well as reducing the variation for any shot length the customer requests between 9090 and 300300 cm.客户要求投射最长距离并且公差为+/-15.0+/-15.0 厘米.改进投石器满足客户要求,同时降低变差.客户要求投射距离为9090 到 300300 厘米之间.Remember切记.D D MM A A D D V V2024/4/21 周日可编辑11Exercise:Safety Analysis&ReviewExercise:Safety Analysis&Review练习练习:安全分析和评审安全分析和评审A review of potential safety hazards is A review of potential safety hazards is in order BEFORE use.in order BEFORE use.潜在安全隐患在审潜在安全隐患在审查后才可使用查后才可使用.Please Consider:Please Consider:请考虑以下内容请考虑以下内容:1.1.Types of potential hazardsTypes of potential hazards潜在隐患类型潜在隐患类型2.2.Frequency of use or exposure to hazardsFrequency of use or exposure to hazards使用频率或者暴漏的隐患使用频率或者暴漏的隐患3.3.Training and expertise of personnel Training and expertise of personnel using equipmentusing equipment培训和专业人员使用的设培训和专业人员使用的设备备4.4.Unexpected or unforeseen hazardsUnexpected or unforeseen hazards意外意外或不可预测的安全隐患或不可预测的安全隐患5.5.Use your issues list to document the Use your issues list to document the potential safety problemspotential safety problems利用问题列表记利用问题列表记录潜在安全问题录潜在安全问题.ToolsMaster Issues Workbook.xls.ToolsMaster Issues Workbook.xls.Lesson PlansRB Storyboard.xls.Lesson PlansRB Storyboard.xlsD D MM A A D D V V2024/4/21 周日可编辑12Safety Analysis Review安全分析评审Several hazards have been detected in Several hazards have been detected in previous training previous training 之前培训过程发现的几种潜在安全隐患之前培训过程发现的几种潜在安全隐患1.1.Dropping the catapult on oneDropping the catapult on ones or s or someone elsesomeone elses foot.s foot.投石器掉下来砸到脚上投石器掉下来砸到脚上.2.2.Looking down the bore of a loaded Looking down the bore of a loaded catapult.catapult.观察已经观察已经“上膛上膛”的投石器的投石器.3.3.Shooting an object not designed for the Shooting an object not designed for the catapult(car keys,golf balls,fruit,catapult(car keys,golf balls,fruit,marbles,a handful of paper clips,6 Sigma marbles,a handful of paper clips,6 Sigma notes,cell phone,etc.)notes,cell phone,etc.)投射其他物品投射其他物品(车钥匙车钥匙,高尔夫球高尔夫球,水果水果,弹珠弹珠,曲别针曲别针,手机手机)4.4.Aiming the catapult at a senior manager Aiming the catapult at a senior manager and claiming the subsequent shot and claiming the subsequent shot“was was an accidentan accident”.将投石器瞄准高级经理并声明将投石器瞄准高级经理并声明这个投射这个投射“是个意外是个意外”.D D MM A A D D V V2024/4/21 周日可编辑13Safety Analysis安全分析安全分析Critical tasksCritical tasks关键任务关键任务qqAdjusting the bandAdjusting the band调整橡胶带调整橡胶带qqAdjusting the launch arm Adjusting the launch arm positionposition调整发射臂的位置调整发射臂的位置qqAdjusting the stop positionAdjusting the stop position调整挡调整挡块位置块位置qqAdjusting the band tension Adjusting the band tension positionposition调整橡胶带拉力板的位置调整橡胶带拉力板的位置Critical hazardsCritical hazards关键安全隐患关键安全隐患qqSpring tension releaseSpring tension release胶带拉力释胶带拉力释放放qqRapid energy releaseRapid energy release快速能量释放快速能量释放qqPotential to be struck by moving Potential to be struck by moving partsparts可能被移动的部件打到可能被移动的部件打到qqPinch points Pinch points 夹点夹点qqImproper use or adjustmentImproper use or adjustment不适不适当的使用或调整当的使用或调整D D MM A A D D V V2024/4/21 周日可编辑14Operation issuesOperation issues操作问题操作问题1.1.Proper adjustment and Proper adjustment and tightening of all bolts and pinstightening of all bolts and pins适适当的调整并拧紧所有螺栓和销轴当的调整并拧紧所有螺栓和销轴2.2.Inspecting the catapult Inspecting the catapult components for obvious defects components for obvious defects 检查投石器明显的缺陷部件检查投石器明显的缺陷部件3.3.Not over stretching the bandNot over stretching the band不要不要过度拉伸橡胶带过度拉伸橡胶带4.4.Do not modify the band by Do not modify the band by shortening it or knotting it.shortening it or knotting it.不要通不要通过缩短或打结的方式调试橡胶带过缩短或打结的方式调试橡胶带5.5.Make sure that all bolts are Make sure that all bolts are tightened BEFORE operatingtightened BEFORE operating在操在操作前确保所有的螺栓都已拧紧作前确保所有的螺栓都已拧紧6.6.One person should operate the One person should operate the armarm一个人操作发射臂一个人操作发射臂Safety Analysis安全分析安全分析D D MM A A D D V V2024/4/21 周日可编辑15Safety precautions安全保护措施Warnings警告qqAllAll adjustments MUST be made with the adjustments MUST be made with the device at device at zero energy statezero energy state,that is with,that is with the spring tension released.the spring tension released.所有的调整必所有的调整必须在须在 “零能量状态零能量状态”，就是橡胶带是松弛状，就是橡胶带是松弛状态态.qqCatapult must not be Catapult must not be“drydry”fired.fired.投石器投石器不能不能“干干”发射发射.qqNEVERNEVER point the catapult at a person point the catapult at a person(even if you do not like them).(even if you do not like them).绝对不能将绝对不能将投石器对准任何人投石器对准任何人(哪怕是个你不喜欢的人哪怕是个你不喜欢的人)qqEnsureEnsure that all personal are clear from that all personal are clear from the anticipated impact area by a safe the anticipated impact area by a safe distance.distance.确保所有人都在安全范围内确保所有人都在安全范围内.D D MM A A D D V V2024/4/21 周日可编辑16Safety Review Safety Review Items for the Tollgate Items for the Tollgate安全评审安全评审-阶段评审项目阶段评审项目qqSafety review components are identified as RED,Safety review components are identified as RED,Yellow and Green for risk analysis.Yellow and Green for risk analysis.安全评审部件按安全评审部件按照风险分析分为红色照风险分析分为红色,黄色和绿色黄色和绿色.qqOverall assessment of Safety review is given Overall assessment of Safety review is given same classification.same classification.安全评审的整体评估是同样的等级安全评审的整体评估是同样的等级.qqTollgate reviews must require Safety reviews to Tollgate reviews must require Safety reviews to take corrective actions to address yellow overall take corrective actions to address yellow overall Review assessment.Review assessment.阶段审查必须要求安全评审采取阶段审查必须要求安全评审采取纠正措施，以解决纠正措施，以解决”黄色黄色”风险的全面审查评估。风险的全面审查评估。qqTollgate Reviews should not be passed Tollgate Reviews should not be passed with with“RedRed”Review items.Review items.阶段评审不能越过阶段评审不能越过 “红色红色”评审项目评审项目