人為失誤質(zhì)量問(wèn)題培訓(xùn)

1、1WCM基礎(chǔ)知識(shí)培訓(xùn)4M1E1DMANMETHODMACHINEMATERIALTrainingOPLSOPPOKA YOKEVisual aidSOPJESVisual aidQuick kaizenStandard kaizenMajor kaizenInput controlQuick kaizenStandard kaizenMajor kaizenStandard kaizenMajor kaizenX matrixQM matrixPPA - DOE市場(chǎng)反饋MARKETKPIs(CPA,TDF)綠標(biāo) BVBuyoff 交付區(qū)返修 /廢品Repair and scrapWCM-QC

2、FLOW 工作流程ENVIR.DESIGNSOPJESVisual aidQuick kaizenStandard kaizenMajor kaizenStandard kaizen2WCM基礎(chǔ)知識(shí)培訓(xùn)人為失誤管理流程 Human error management flow1，記錄人為失誤 Record the human error2，要求作業(yè)員填寫人為失誤卡 Human error card filling by operater3，TWTTP&HERCA 的原理 TWTTP&HERCA Theory4，工段長(zhǎng)或班長(zhǎng)對(duì)作業(yè)員進(jìn)行 TWTTP&HERCA UTE le

3、ader and team leader apply TWTTP towards operator5，選擇適當(dāng)?shù)墓ぞ呓鉀Q問(wèn)題 Choose suitable tool for the human error6，5QF0D表格總結(jié) 5Q for 0 defects fulfillment7，填寫改善，總結(jié)收益和損失 Make kaizen to know the benefit and cost.3WCM基礎(chǔ)知識(shí)培訓(xùn)人為失誤序號(hào)Human Error No.人為失誤描述Human Error description發(fā)生工段Responsible UTE重復(fù)發(fā)生標(biāo)紅Red is repetitiv

4、e 月份Monthly occurrence 1，記錄人為失誤 Record the human error4WCM基礎(chǔ)知識(shí)培訓(xùn)2，要求作業(yè)員填寫人為失誤卡 Human error card filling by operator人為失誤卡用于作業(yè)員對(duì)作業(yè)進(jìn)行自我反省和自我教育，同時(shí)還可以將此次發(fā)生的人為失誤跟蹤管理起來(lái)，這樣可以大幅度降低人為失誤的發(fā)生率。Human error card is aim to help operators to make a self education which include how the error happened and how to opera

5、te correctly. At the same time ,we can manage this human error to monitor the trend. In this way ,the human error will be decreased.問(wèn)題序號(hào)Error no.問(wèn)題名稱Error name錯(cuò)誤手法Wrong way正確手法Correct way姓名 Name年份 Year5WCM基礎(chǔ)知識(shí)培訓(xùn)3，TWTTP&HERCA 的原理 TWTTP&HERCA Theory工藝設(shè)計(jì)Process design作業(yè)指導(dǎo)書(shū)SOP工作環(huán)境和條件Environment

6、and condition is not sufficient不專心或者健忘Inattentiveness or forgetfulness 工具和設(shè)備Tools and equipment人為失誤HUMAN ERROR員工激勵(lì)和積極性Motivation and involvement是否缺乏培訓(xùn)？Lack of training?OTHER 其它其它OJT 在崗在崗培訓(xùn)培訓(xùn)COACHING 指導(dǎo)指導(dǎo)/輔導(dǎo)輔導(dǎo)VISUAL MGMT 目視目視管理管理OPLSOPAM/WO 方法方法3M 分析分析KAIZEN 改善改善MISTAKE PROOF 防錯(cuò)防錯(cuò)ERROR PROOF 防誤防誤YESN

7、O6WCM基礎(chǔ)知識(shí)培訓(xùn)4，工段長(zhǎng)或班長(zhǎng)對(duì)作業(yè)員進(jìn)行 TWTTP&HERCA UTE leader and team leader apply TWTTP towards operatorINTERVIEW: TWTTP (The Way to Teach People) 采訪采訪:TWTTP (教人的方法教人的方法)1ST INTERVIEW / TWTTP 第第1次訪談次訪談(Explanations / Operator answer)(解釋解釋/操作員回答操作員回答)Evaluation 評(píng)估評(píng)估1How do you do this work? “你是怎么做這項(xiàng)工作的你是怎么做

8、這項(xiàng)工作的?”Do you understand the activities that you are performing? (Explain what, how and why) 你是否理解你所執(zhí)行的操作你是否理解你所執(zhí)行的操作?(解釋什么解釋什么,怎樣怎樣,為什么為什么)1xAYes 是的是的Lack of Knowledge 缺乏知識(shí)缺乏知識(shí)AXBNot completely 不完全不完全BCNo 不知道不知道C2How do you know you are doing this work correctly? 你怎么知道你所做工作是正你怎么知道你所做工作是正確的確的?How ca

9、n you verify that youre working correctly?你怎么能證明你工作正確？你怎么能證明你工作正確？2xAI follow the work instruction and posted standard (SOP, OPL, etc. Have operator explain what how and why) 我按照作業(yè)指導(dǎo)書(shū)和崗位標(biāo)準(zhǔn)我按照作業(yè)指導(dǎo)書(shū)和崗位標(biāo)準(zhǔn)(SOP,OPL等等,操作員解釋什么操作員解釋什么,怎樣怎樣,為什么為什么)Lack of Knowledge 缺乏知識(shí)缺乏知識(shí)AXBI automatically know what to do

10、based on my own experience 我根據(jù)自我根據(jù)自己經(jīng)驗(yàn)自動(dòng)知道做什么己經(jīng)驗(yàn)自動(dòng)知道做什么BCOther (describe) 其它其它(描述描述)C3How do you know that the outcome is free of defects?你怎么知道生產(chǎn)出的產(chǎn)品是你怎么知道生產(chǎn)出的產(chǎn)品是沒(méi)有問(wèn)題的沒(méi)有問(wèn)題的?How do you know that you performed your operation without any defects?你怎么你怎么知道你執(zhí)行的操作沒(méi)有任何問(wèn)題知道你執(zhí)行的操作沒(méi)有任何問(wèn)題?3xAI received feedback

11、 from the nearest quality check or source 我從最近的我從最近的質(zhì)量門得到反饋質(zhì)量門得到反饋Lack of Knowledge 缺乏知識(shí)缺乏知識(shí)AxBI automatically know by experience 我通過(guò)經(jīng)驗(yàn)會(huì)自動(dòng)知我通過(guò)經(jīng)驗(yàn)會(huì)自動(dòng)知道道BCOther (describe) 其它其它CX4What do you do if you have a problem?如果有問(wèn)題你會(huì)怎么做如果有問(wèn)題你會(huì)怎么做?What do you do in case of problems?當(dāng)有問(wèn)題時(shí)你會(huì)怎么做當(dāng)有問(wèn)題時(shí)你會(huì)怎么做?4xAI immed

12、iately alert my team leader / Direct Responsible / Supervisor / Unit Leader or follow the reaction plan for the station 我立即告訴班長(zhǎng)我立即告訴班長(zhǎng)/直接責(zé)任人直接責(zé)任人/組長(zhǎng)組長(zhǎng)/工段長(zhǎng)或采取工段長(zhǎng)或采取緊急措施緊急措施Lack of Knowledge 缺缺乏知識(shí)乏知識(shí)ABI only talk to my team leader or supervisor when they ask me questions 我只告訴我的班長(zhǎng)我只告訴我的班長(zhǎng)/工段長(zhǎng)當(dāng)他工段長(zhǎng)當(dāng)他們問(wèn)我

13、的時(shí)候們問(wèn)我的時(shí)候BXCOther (describe) 其它其它(描述描述)C依次問(wèn)作業(yè)員四個(gè)問(wèn)題，根據(jù)作業(yè)員的回答填寫到空白中，并對(duì)內(nèi)容進(jìn)行評(píng)估A,B,C的等級(jí)。Ask operator four question and fill the answer into blank then evaluate the level of A,B,C.空白內(nèi)填寫作業(yè)員的回答的內(nèi)容 Fill the blank with operators answer根據(jù)ABC的描述評(píng)估并選擇等級(jí) Evaluate and choose the level according to ABC description如

14、果四個(gè)問(wèn)題答案不都是A，則進(jìn)入下一頁(yè)P(yáng)PT，否則跳過(guò)直接進(jìn)入HERCA。If 4 questions are not all A, go to next page ,or jump into HERCA.7WCM基礎(chǔ)知識(shí)培訓(xùn)4，工段長(zhǎng)或班長(zhǎng)對(duì)作業(yè)員進(jìn)行 TWTTP&HERCA UTE leader and team leader apply TWTTP towards operator當(dāng)作業(yè)員缺乏知識(shí)和技能導(dǎo)致了人為失誤，需要進(jìn)行細(xì)節(jié)分析，并選擇相應(yīng)的工具解決此問(wèn)題。When the human error is caused by lack of knowledge and skil

15、l, we need to do detail analysis to find the tool improve training.如果回答如果回答結(jié)果都是結(jié)果都是A,直接進(jìn)入直接進(jìn)入HERCA.Jump into HERCA如果不都是如果不都是A，進(jìn)入細(xì)節(jié)分進(jìn)入細(xì)節(jié)分析析If answers are not all A, go to detail analysis8WCM基礎(chǔ)知識(shí)培訓(xùn)5，選擇適當(dāng)?shù)墓ぞ呓鉀Q問(wèn)題 Choose suitable tool for the human error根本原因ROOT CAUSE解決工具解決工具Contermeasures9WCM基礎(chǔ)知識(shí)培訓(xùn)6，5QF

16、0D表格總結(jié) 5Q for 0 defects fulfillment#ManANSWER1351Is the needed training/competence defined to complete operation correctly?Training/competence is not defined.Training/competence is defined but could be clearer. Training/competence is clearly defined and training/competence gaps are easily identifiab

17、le. ( exe. Radar Chart).2How is the training/competence gap covered?Only class room training.More class room training than training on the job/MTS.More training on the job (including MTS) than class room training.3 Can the operator follow the standard (i.e. VSOP, SWI/OPL,)The standards are not follo

18、wed.The standards are often followed.The standards are always followed.4Is the human error detectable?Most of human errors will not be detected.A method to detect exists, but it is not robust (exe. Downstream visual check, push/pull/push). All human errors are detected and analyzed (Example Q gate/Error/Mistake/ Alarming).5Is there an on-going training system?Refresher training is not done