精益生產(chǎn)防錯

ErrorProofing

防錯Topics-ErrorProofingTraining

Topics主題ObjectivesoftheTraining培訓(xùn)的目的WhatandWhyofErrorProofing什么是防錯，怎樣進行防錯ApplicationofErrorProofing防錯應(yīng)用IdentifyOpportunitiesforErrors防錯時機的確定OverviewofFailureModeandEffectsAnalysis(FMEA)失效模式和效果分析總括ErrorProofingOptions防錯的選擇Prevention&DetectionThroughPokaYokeDevices通過PokaYoke進行預(yù)防與探測MovetoTheNextLevel轉(zhuǎn)入下一級ABenchmarkWithinEaton伊頓內(nèi)部標準Summary概要ObjectivesoftheTraining

培訓(xùn)的目的UnderstandWhatIsErrorProofingandWhatItCanDo了解什么是防錯和防錯能做什么UnderstandthePrinciplesofErrorProofing了解防錯的原理LearnHowtoApplyErrorProofingtoProductsandProcesses了解怎樣對產(chǎn)品及工藝過程應(yīng)用防錯LearnAboutthePokaYokeDevicesandSystems了解PokaYoke裝置和系統(tǒng)LearntheProcessofImplementationandContinuousImprovements了解實施防錯的過程和持續(xù)改進的過程WhatAreYourExpectations?

你們的期望是什么？WhatandWhyofErrorProofing

什么是防錯以及為什么要防錯Definition

定義ErrorProofingIsaSystematicApproachforAnticipatingandDetectingPotentialDefectsandPreventingThemFromReachingtheCustomer(InternalorExternal)防錯是一種預(yù)測及探測潛在缺陷以及阻止缺陷影響客戶的體系方法(內(nèi)部防錯和外部防錯)ErrorProofingbyOtherNames

以其他名稱進行防錯FoolProofing防止愚蠢行為IdiotProofing防止白癡行為MistakeProofing防止錯誤行為FailSafing安全失效PokaYokeZeroQualityControl(ZeroDefects)零質(zhì)量控制（零缺陷）DesignforManufactureandAssembly制造和裝配的設(shè)計LetUsNotArguetheMeritsofTheseNamesLetUsDecideWhatWeWanttoAchieve我們不要爭論這些名稱,讓我們決定想要完成什么?DemoralizingTerms防錯術(shù)語CharacteristicsofErrorProofing

防錯的特點ProactiveIdentificationandPrevention前期識別及預(yù)防PreventFirst首先進行防錯DoNotAllowDefectFromGoingFurther其次不準許缺陷進一步發(fā)展IntentionallyDesigned,NotHappenstance設(shè)計錯誤,非偶然錯誤.AttheSource-ClosetotheOrigination錯誤的來源_接近發(fā)源地.InexpensiveFirst首先成本不高TransparenttotheOperator操作者很容易發(fā)現(xiàn)AbsolutelyReliable錯誤根源查找絕對準確AMeanstoAchieveZeroDefectProduct一種達到0缺陷產(chǎn)品的方法DefectsinProductsAretheImperfections(orFaults,orFlaws,orBlemishes,orShortcomings,orFailings,orDeficiencies)

缺陷是指產(chǎn)品里的不完整性(或者故障,或者裂紋,或者瑕疵，或者短處，或者過失，或者不足)ResultingFromErrors錯誤產(chǎn)生的結(jié)果ErrorsAreHumanOversights(orFaults,orBlunders,orBoo-boos,orSlip-ups,orInaccuraciesorMiscalculations)ThatCauseDefectsinProducts錯誤是人為疏忽(或者過錯,或者失誤,或者低級錯誤，或者失敗，或者精度失誤或者計算失誤)，這些引起產(chǎn)品的缺陷。DefectsandErrors

缺陷和錯誤SO,ErrorsCauseDefectiveProducts!!所以,錯誤導(dǎo)致有缺陷的產(chǎn)品產(chǎn)生!!WhyAreErrorsMade為什么會會導(dǎo)致錯錯誤AnyProductIsaResultofNumerousDecisionsMadeandActionsTakenbyHumanBeings,During:任何產(chǎn)品品都可以以在下述述一系列列人為行行為中產(chǎn)產(chǎn)生錯誤誤：ProductDesign產(chǎn)品設(shè)計計ProcessDesign過程設(shè)計計EquipmentDesign設(shè)備設(shè)計計ComponentFabricationProcesses零件加工工過程ProductAssemblyProcesses產(chǎn)品裝配配過程InspectionProcesses檢驗過程程PaperworkGeneration程序行程程過程Etc.等等AndHumanBeingsareFallibleorImperfect人是容易犯錯錯或不完美的的SOMEExamplesofDefects屬于缺陷的一一些例子WrongorInappropriateMaterial錯誤或不適合合的材料WrongorNon-functioningComponents錯誤或者沒有有功能的零件件WrongDimensionsorTolerances尺寸或公差錯錯誤MissingComponents零件漏裝ForeignMatters,Contamination雜質(zhì)物質(zhì),污穢物DamagedProductorComponents受損產(chǎn)品或零零件WrongPaperwork,orWrongProductShipped程序錯誤或者者運輸了錯誤誤的產(chǎn)品Non-functioningorMalfunctioningProduct沒有功能的的產(chǎn)品或者者是故障產(chǎn)產(chǎn)品WrongShipping,orWrongBilling運輸錯誤或或者是填單單錯誤SOMEExamplesofCausesofDefects導(dǎo)致缺陷的的一些例子子PoorDesignDecisions設(shè)計比較乏乏味OmittedorWrongProcessing過程疏忽或或過程錯誤誤Missing/ExtraPartsorWrongParts漏裝/多裝裝了錯誤的的零件OmittedorWrongAdjustment/Testing遺漏漏調(diào)調(diào)整整/測測試試或或調(diào)調(diào)整整/測測試試過過程程錯錯誤誤WrongEquipmentSetuporLossofSetup設(shè)備設(shè)設(shè)置錯錯誤或或沒有有進行行設(shè)備備設(shè)置置WrongMaterial,ComponentsorAssemblies材料，，零件件或者者裝配配錯誤誤WrongCommunication,Instructions,Procedures,orMethods錯誤的的信息息，指指令，，程序序，或或者方方法Inexperience,LackofTraining,WrongTraining,LackofRetraining缺乏經(jīng)經(jīng)驗，，缺乏乏培訓(xùn)訓(xùn)，培培訓(xùn)錯錯誤，，缺少少再培培訓(xùn)SOMEExamplesofResultsofDefects缺陷導(dǎo)致致的結(jié)果果示例MalfunctionorNon-functioningProduct有故障或或者缺乏乏機能的的產(chǎn)品Inconvenience,Discomfort,Injury,Death麻煩，不不便，傷傷害，死死亡Delays,Cancellations延期，取取消FinancialLosses財政損失失LossofUseorProductivity效用或者者生產(chǎn)力力的缺乏乏DamagetoCustomer’’sProperty損害客戶戶的利益益LiabilitiesandLawSuites負債和法法律問題題LossofReputationandBusiness名譽和業(yè)業(yè)務(wù)受損損SOMECausesofHumanErrors導(dǎo)致人們們犯錯誤誤的一些些原因Forgetfulness,LossofConcentration,LackofAttentionorDivertedAttention健忘，不不集中，，缺乏注注意力或或者轉(zhuǎn)移移注意力力MisunderstandingorLackofUnderstanding誤會或者者缺乏理理解LackoforImproperExperience/Training缺乏經(jīng)驗驗/培訓(xùn)訓(xùn)或者不不正確的的經(jīng)驗/培訓(xùn)LackofStandardization缺乏標準準IntentionalorWillfulError有意圖的的或者惡惡意的錯錯誤WrongorDelayedDecision決定錯誤誤或拖延延LimitedorLackofSensoryCapability(e.g.,Smell,Color,Touch)有限的或或者沒有有感官能能力（例例如，嗅嗅覺，色色彩，觸觸覺）LackofApplicationofCommonSense缺乏運用用常識判判斷的能能力ErrorProofinginaFewWords預(yù)防錯誤誤的一些些方法“…occurrenceofdefectwastheresultofsomeconditionoraction,andthatitwouldbepossibletoeliminatedefectsentirelybypursuingthecause.Thecausesofdefectslieinworkererrors,anddefectsaretheresultsofneglectingthoseerrors.Itfollowsthatmistakeswillnotturnintodefectsifworkererrorsarediscoveredandeliminatedbeforehand.”缺陷的產(chǎn)產(chǎn)生是一一些環(huán)境境或者行行為導(dǎo)致致的結(jié)果果，但是是完全有有可能通通過查找找原因排排除缺陷陷。缺陷陷原因在在于工人人，缺陷陷是因為為工人忽忽視錯誤誤而產(chǎn)生生的。如如果工人人能及時時的發(fā)現(xiàn)現(xiàn)錯誤并并且消除除錯誤，，就不會會導(dǎo)致缺缺陷的產(chǎn)產(chǎn)生。ShigeoShingoWhyErrorProof?為什么防錯錯？99.9%ErrorFreeCouldResultin99.9%沒有錯誤誤導(dǎo)致什么么結(jié)果2,000,000DocumentsLostbyIRSIRS缺少2，000，000檔案案16,000PiecesofMailLostEveryDay每天丟失16，000郵件22,000WronglyDebited/CreditedChecksPerHour每個小時都都會發(fā)生22，000寫錯借借方和貸方方的支票1,314WronglyConnectedPhoneCallsPerMinute每個小時都都會發(fā)生1，314起電話占占線20,000IncorrectDrugPrescriptionsPerYear每個小時都都會發(fā)生20，000起用錯錯藥物的情情況12NewbornBabiesGiventoWrongParents12個小孩孩被父母抱抱錯2UnsafeLandingsEveryDayatO’’HareAirport每天都會有有2起飛機機不安全著著陸32,000MissedHeartbeatsPerPersonEachYear每年每個人人都會有32，000Is99.9%GoodEnough???99.9%夠不夠好???TheErrorsThatBecameHeadlines錯誤變成頭頭條TitanicSinking泰坦尼克號號的沉沒ChallengerBoosterRocketSealFailure挑戰(zhàn)者號火火箭發(fā)射失失敗MarsLandingModuleCrash火星升空失失敗墜毀HubbellTelescopeReflectorErrorHubbell望遠鏡反射射誤差ExxonValdezOilSpillExxonValdez石油泄露ChernobylNuclearPowerPlantMeltdownChernobylNuclearPower設(shè)備報廢ReleaseofMethylIsocyanate(MIC)FromUnionCarbidePlantinBhopal,India甲基異丙酮酮從Bhopal,India,MIC碳化物廠房房泄露ThreeMileIslandNuclearPlant三英里小島島的核廠房房FirestoneTiresonFordExplorer福特車上的的耐火石探探測器ErrorProofingandLean防錯及精益益生產(chǎn)LeanInsistsonOnePieceFlow精益生產(chǎn)強強調(diào)單件流流IfThatOnePieceIsDefective,FlowIsDisrupte如果單件流流有缺陷,流向就會會被打斷LeanInsistsonLimitedInventory精益生產(chǎn)強強調(diào)有限庫庫存IfThatInventoryIsDefective,theLinesCanSto如果庫存有有缺陷,線線路就會停停止LeanMeansEliminatingWaste精益是指消消除浪費DefectsandCorrectiveActionsAreWast缺陷以及糾糾正措施是是針對浪費費LeanRequiresThatEquipmentIsReadyWhenNeededandFunctionsWellAsLongAsNecessary精益生產(chǎn)要要求當(dāng)需要要設(shè)備時,設(shè)備馬上上可以用,且功能完完好ErrorProofingtheTools,Fixtures,Setups,MethodsandDocumentsEnsuresEquipmentEffectiveness刀具,卡具具,啟動,方法以及及文件等防防錯以確保保設(shè)備的有有效性ErrorProofingExamplesinEverydayLife在每天生活活中防錯的的一些例子子Home家里AutomaticShutoffIrons全自動熨斗GroundFaultCircuitBreakersforBathroomorOutdoorElectricCircuits浴室或室外外電氣線路路的接地保保護PilotlessGasRangesandHotWaterHeaters油量表以及及熱水器Child-ProofCapsonMedicineBottles藥瓶上保護小孩安安全的瓶蓋蓋Retail零售Tamper-ProofPackaging錐型防錯包裝BarCodingatCheckou檢驗時的條碼Office辦公室SpellCheckinWordProcessingSoftware在Wordword處處理軟件中中進行拼寫檢檢查Verifying“Doyouwanttodelete?”WhenPressthe“Delete”ButtononYourComputer當(dāng)按刪除按鈕鈕時電腦會會詢問你““要刪除嗎嗎”?Factory工廠DualPalmButtonsandOtherGuardsonMachinery設(shè)備上使用兩個按按扭及其他他保護裝置置BarCoding條碼Lock-Out/Tag-Out鎖緊/打開標簽ErrorProofingExerciseNo.1防錯練習(xí)的的第一部分分FormTeamsofTwo兩個一組ListAsManyExamplesofErrorProofingAsYouCan,FromEverydayLife從你每天的的生活中,列出你能作作到的關(guān)于于防錯的許許多例子10Minutes10分鐘ApplicationofErrorProofing防錯的應(yīng)用用EssentialStepsforErrorProofing防錯的基本本步驟IdentifyOpportunitiesforErrors(CriticalFactors)識別防錯的的時機(關(guān)鍵因素)PrioritizePotentialErrorsforErrorProofing對潛在的錯錯誤加以，，區(qū)分進行行防錯AbsolutelyMustPreventtheDefects必須完全的的防止錯誤誤ProvideContainmentandStudyFurther預(yù)防錯誤和和深入研究究MayBeTolerated,WithinPredefinedLimits在計劃的范范圍內(nèi)進行行防錯IdentifyRootCausesoftheErrors識別錯誤根根源DevelopandEvaluateErrorProofingOptions開發(fā)和評估估防錯方案案Selectand“Design”theErrorProofingSystem選擇和設(shè)計計防錯系統(tǒng)統(tǒng)Implement-Plan,Install,Document,Train,Monitor實施防錯－－設(shè)計反錯錯，安裝防防錯,編制防錯文文件,培訓(xùn),監(jiān)控PeriodicallyAssessthePerformanceandImprove對防錯情況況進行定期期評審及改改進ManufacturingProcesses制造過程ProductQuality產(chǎn)品質(zhì)量ProcessDesign過程設(shè)計ProductDesign產(chǎn)品設(shè)計WhatistheRightTimetoErrorProof??正確的防錯錯時間是什什么時間?100:110:11:1AsEarlyAsPossible及早發(fā)現(xiàn)WhyErrorProofEarlyDuringNewProductDevelopment為什么在新新產(chǎn)品開發(fā)發(fā)期間防錯錯Costof““Fixing”theDefects““修理”缺陷陷的成本ConceptDevelopment觀念開發(fā)PreliminaryDesign初步設(shè)計DetailedProductDesign詳細的產(chǎn)品品設(shè)計CustomerSupport客戶支持Industrialization產(chǎn)業(yè)化Production生產(chǎn)ProcessDesign過程設(shè)計Costof““Fixing”設(shè)備的花費費MultipliesWithLifeCycleStages整個過程當(dāng)當(dāng)中的多項項防錯StagesofProductLifeCycle產(chǎn)品品生生命命周周期期中中各各個個階階段段WhyErrorProofEarlyDuringProcessing在處處理理期期間間為為什什么么要要盡盡早早防防錯錯Costof““Fixing””theDefects設(shè)備備成成本本失失效效IncomingParts外協(xié)協(xié)件件AfterCompletingtheProcess過程程完完成成之之后后AttheEndoftheLine產(chǎn)品最最終離離開生生產(chǎn)線線AfterDeliverytoCustomer交付給客戶戶之后FinalTest最后檢驗Costof““Fixing”IncreasesWithProcessSteps隨著程序步步驟增長修修復(fù)錯誤成成本增長StepsofProductProcessing產(chǎn)品處理的的步驟Reject&Return廢棄件NoDelay沒有拖延Reject&Scrap廢棄件&廢廢品MinorDelay稍微拖延Reject&Scrap/Rework廢棄件&廢廢品/返工工RescheduleSomeDelay進度稍有拖拖延SignificantRework/ScrapAddtotheProductionScheduleDelayedDeliveries重要的返工工/廢品影影響生產(chǎn)進進度及產(chǎn)品品交付WarrantyCostsAdministrativeCostsLiabilitiesReputationMarketShareLoss擔(dān)保成本及及管理成本本增加,導(dǎo)導(dǎo)致市場份份額損失ErrorProofingExerciseNo.2防錯訓(xùn)練的的第二部分分FormTeamsofTwo兩個一組DiscussandAgreeonOneExampleofProductDesignorManufacturingProcesstoAnalyze討論一個個產(chǎn)品設(shè)設(shè)計或制制造工藝藝的例子子,并進進行分析析Identify鑒別ErrorProofingImplemented防錯實施施EstimateCost/QualityImpact消除成本本/質(zhì)量量影響OR或者ErrorProofingOpportunitiesMissed喪失防錯錯良機EstimatetheCost/QualityImpact消除成本本/質(zhì)量量影響ListLessonsLearned學(xué)到的教教訓(xùn)清單單PreparetoPresenttotheClass準備到課課堂上展展示20Minutes20分鐘IdentifyOpportunitiesforErrors識別防錯錯的時機機MethodsforIdentifyingPotentialErrors識別潛在在的防錯錯方法CustomerDemanded-GoodStart消費者的的需求-良好的的開始InternalQualityResults––Reactive內(nèi)部質(zhì)量量成效-反應(yīng)PastExperience-NotCompletelyReliable以往經(jīng)驗驗-不完完全可靠靠Customer反饋-TooLate消費者的的反饋-太遲SystematicAnalysestoIdentifyPotentialErrors識別潛在在的錯誤誤需進行行系統(tǒng)分分析PotentialFailureModeandEffectsAnalysis(FMEA)潛在的失失效模式式及效果果分析(FMEA)ProductFMEA產(chǎn)品FMEAProcessFMEA過程FMEAPotentialFailureModeandEffectsAnalysesPFMEA潛在的失失效模式式和效效果分分析Overview總攬KeyPointsofFMEAFMEA的關(guān)鍵部部分FMEAAnalysesPotentialFailuresFMEA分析潛在在失效FleasHavetoBeDonebyMulti-functionalTeamsFleas應(yīng)由多功功能組執(zhí)執(zhí)行DesignFMEAShouldBeInitiatedBeforeorattheConceptStage設(shè)計FMEA是在開始始之前或或者概念念形成階階段ProcessFMEAShouldBeInitiatedBeforeorattheFeasibilityStage,PriortoToolingorEquipmentFinalization過程FMEA是在工裝裝及設(shè)備備調(diào)整好好開始生生產(chǎn)之前前或者可可研階段段FMEAsShouldBeContinuouslyUpdated,AsChangesinProduct&ProcessDesignsTakePlace應(yīng)該不斷更更新,比如如FMEAs中的產(chǎn)品&過程設(shè)計計FMEAsAreLivingDocumentsFMEAs是活的文件件FMEAsAreNeverEndingProcessesFMEAs是永遠都不不會結(jié)束的的工藝FMEATypeandLevelsFMEA的類型和水水平DesignFMEA設(shè)計FMEAProcessFMEA過程FMEASubsystem子系統(tǒng)CriticalFeatures關(guān)鍵特性Components/Parts零件Subassemblies分裝Workstations工作臺Operations加工操作GeneralInformation(1)總說明23456781011912FMEAStepsFMEA的步驟DesignFMEA設(shè)計FMEAGeneralInformation-DetailsoftheProduct&FMEA信息息總總說說明明-產(chǎn)產(chǎn)品品及及FMEA的詳詳情情ItemFunction/Requirement項目目的的功功能能/要要求求EnterAllFunctionsofaProductItem鍵入入所所有有產(chǎn)產(chǎn)品品的的功功能能PotentialFailureMode潛在的故故障模式式DescribeHowaProductItemCouldFail描述產(chǎn)品品怎樣失失效UsePhysicalTerms,NotSymptoms使用專用用描述詞詞語,不不是癥狀狀ProcessFMEA過程FMEAGeneralInformation-DetailsoftheProduct&FMEA信息總說說明--產(chǎn)品品的詳細細資料和和FMEAProcessFunction過程功能能EnterDescription&PurposeoftheProcess鍵入過程程描述和和過程功功能PotentialFailureMode潛在失效效模式DescribeHowProcessCouldFailtoMeetRequirementsofSubsequentOperations描述工藝藝為什么么不能滿滿足分序序要求DescribeNon-conformance描述不一一致性FMEAStepsFMEA的步驟驟DesignFMEA設(shè)計FMEAPotentialEffect(s)ofFailure潛在失失效效效果PerceivedbyCustomer客戶需需要Severity(Chart)嚴肅性（圖表表）SeriousnessoftheEffectofPotentialFailure潛在失效效果果的嚴肅性SeverityRankingReducedOnlybyDesignChange只有設(shè)計更改改時嚴肅性級級別降低Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或或功能/基本本表象EmployCustomer’’sCriteria采用客戶標準準ProcessFMEA過程FMEAPotentialEffect(s)ofFailure潛在失效效果果PerceivedbyCustomer,IncludingSubsequentOperations客戶需要,包包括下述操作作Severity(Chart)嚴肅性(圖表表)SeriousnessoftheEffectofPotentialFailure潛在失效效果果的嚴肅性Classification分類Safety/RegulationorFunction/AppearanceBased安全/規(guī)定或或功能/基本本表象EmployCustomer’’sCriteria采用客戶標準準SeverityRatingChart嚴肅性級別表表格FMEAStepsFMEA步驟DesignFMEA設(shè)計FMEAPotentialCause(s)潛在原因ListAlltheCauses(DesignWeaknesses)列出所有原因因(設(shè)計弱點)Occurrence(Chart)頻率(圖表)LikelihoodoftheFailuretoOccurbytheSpecificCause特殊原因?qū)е轮率У目赡苣苄設(shè)ccurrenceRankingReducedOnlybyDesignChange僅當(dāng)設(shè)計更改改時才考慮降降低發(fā)生頻率率.DesignControl設(shè)計控制Validation/VerificationActivitiesWhichWillAssureAdequacyofDesign驗證/確認活動應(yīng)確確保設(shè)計的準準確性ProcessFMEA過程FMEAPotentialCause(s)潛在原因IdentifyRootCause,andIdentifyWhatCanBeCorrected確定原因,確定可以采取取什么糾正措措施Occurrence(Chart)頻率(圖表)ExpectedFrequencyofFailuretoOccurbySpecificCause具體原因?qū)е轮率Оl(fā)生的的頻率Classification(Chart)類別ProcessControlsThatPreventorDetecttheFailure預(yù)防或探測缺缺陷的過程控控制OccurrenceRatingChart頻率等級表格格FMEAStepsFMEA的步驟DesignFMEA設(shè)計FMEADetection(Chart)檢測（圖表））AbilityofaCurrentDesignControltoIdentifyaPotentialCause現(xiàn)行控制設(shè)計計能力,以識識別潛在的原原因當(dāng)前設(shè)計的能能力ProcessFMEA過程FMEADetection(Chart)檢測（圖表））AssumingFailureHasOccurred,AssessDetectionCapabilityofAlltheProcessControls假設(shè)發(fā)生失效效,應(yīng)檢測所所有工藝控制制的能力RPN(RiskPriorityNo.)RPN(風(fēng)險優(yōu)先號)ProductofS(Severity),O(Occurrence)&D(Detection)產(chǎn)品的S(嚴重性),O(發(fā)生頻率)&D(檢測)UsedAsaGuidetoHelpRankDesign/ProcessConcerns為進行設(shè)計及及過程等級等等提供向?qū)oThresholdValue無界限值PaySpecialAttentionIfSeverityIsHigh如果嚴重級別別高的話,應(yīng)應(yīng)提高警惕CorrectiveAction,Responsibility,andMonitoringResults實施糾正措施施,確定責(zé)任任人,監(jiān)控結(jié)結(jié)果1112DetectionRatingChart檢測等級表SummarizedRatingChart總結(jié)等級表SummaryofFMEASteps

FMEA步驟匯總FormaMulti-functionalTeam組建多功能小小組FailureMode:HowCouldThisPart,SystemorProcessFail?失效模式:該該產(chǎn)品,系統(tǒng)統(tǒng)或工藝是怎怎么失效的?EffectoftheFailure:WhatDoestheCustomerExperienceAsaResultoftheFailure?失效影響:作作為一種失效效模式客戶的的經(jīng)驗是怎樣樣的?CauseofFailure:WhatConditionsCouldBringAbouttheFailureMode?失效原因:關(guān)關(guān)于該失效模模式會導(dǎo)致什什么情況?Occurrence:ProbabilitytheFailureModeWillOccur發(fā)生:發(fā)生失失效模式的可可能性Severity:WeighingtheConsequenceoftheFailureMode嚴重性:衡量量失效模式的的結(jié)果Detection:ProbabilitytheFailureModeWillNotBeDetectedBeforeReachingtheCustomer失效:失效模模式在到達客客戶之前不會會被檢測到.RiskPriorityNo.(RPN):ProductofOccurrence,SeverityandDetection,ThatProvidesRelativePriority.風(fēng)險號(RPN):產(chǎn)品發(fā)生頻率率,嚴重性檢檢測,提供了了相對優(yōu)先權(quán)權(quán).IdentifyActionItems,AssignResponsibility,andFollowThrough確定實施措施施:分配責(zé)任任,跟蹤執(zhí)行行EssentialStepsforErrorProofing防錯的基本步步驟IdentifyOpportunitiesforErrors(CriticalFactors)PrioritizePotentialErrorsforProofingAbsolutelyMustPreventtheDefectsProvideContainmentandStudyFurtherMayBeTolerated,WithinPredefinedLimitsIdentifyRootCausesoftheErrorsDevelopandEvaluateErrorProofingOptionsSelectand““Design”theErrorProofingSystemImplement-Plan,Install,Document,Train,MonitorPeriodicallyAssessthePerformanceandImproveFMEAAddressesAlltheseErrorProofingStepsFMEA可以定位所有有的防錯步驟驟AndHelpsPlanforThese為此設(shè)置計劃劃Exercise-3

ProcessPFMEA過程PFMEA練習(xí)第三部分分IdentifyOneoftheProcessSteps識別一個過程程步驟WalkThroughtheStepsofPFMEA實施整個PFMEA步驟FillOuttheFMEAForm填寫FMEA表格DevelopanActionPlan開發(fā)實施計劃劃ErrorProofingOptions防錯方案ErrorProofingApproaches防錯方法EliminatePotentialDefects:DesignOutthePotentialsforErrors消除潛在缺陷:對對潛在錯誤進進行設(shè)計PreventDefectsFromOccurring:IdentifythePotentialofError,BeforeItOccurs,andPreventIt防止缺陷發(fā)生生:識別潛在在錯誤:在錯錯誤發(fā)生前進進行預(yù)防DetecttheDefect:ErrorHasAlreadyOccurred,DetectandRemovetheDefectiveProduct檢測缺陷:錯錯誤已經(jīng)發(fā)生生,檢測及移移除缺陷件LossControl:PotentialforDefectExists,PotentialExistsforNotDetecting,MinimizeDamageFromtheDefect損失失控控制制:存存在在潛潛在在缺缺陷陷,沒沒有有對對潛潛在在缺缺陷陷進進行行探探測測,使使缺缺陷陷的的傷傷害害最最小小化化.AllTheseApproachesOverlap,NoClearBoundaries所有有方方法法交交織織在在一一起起,沒沒有有清清晰晰界界限限Example-FireProofingaNewBuilding例如如-新新建建筑筑的的防防火火防防錯錯Eliminate:UseOnlyNon-combustibleMaterialforConstruction(Steel,Concrete,Etc.)排除除：：在在建建筑筑中中要要使使用用不不易易燃燃物物質(zhì)質(zhì)（（鋼鋼鐵鐵，，混混凝凝土土等等））Prevent:DoNotAllow不允允許許吸吸煙煙ElectricalSystemandComponents使用正正確的的電氣氣系統(tǒng)統(tǒng)和元元件預(yù)預(yù)防：：Detect:InstallSmokeDetectorsandFireAlarms檢測：：安裝裝煙霧霧檢測測器和和火警警系統(tǒng)統(tǒng)LossControl:InstallSprinklerSystem,FireExtinguishers,FireHoses損失控控制：：安裝裝自動動噴淋淋裝置置系統(tǒng)統(tǒng)，滅滅火器器，滅滅火水水龍帶帶，防防火軟軟管等等Example-AccidentProofaRailwayCrossing例子：測試試鐵道路口口的意外事事故EliminateAccidents:BuildaBridge排除事故：：建造一座座橋PreventAccidents:InstallanAutomaticGate,InAdditiontoLightsandAlarms預(yù)防意外事事故：除了了燈和警報報裝置,安安裝一個自自動門DetectandannounceaPassingTrain:InstallLightsandAlarms檢測和進進行一個個短期培培訓(xùn)：安安裝燈和和警報裝裝置培訓(xùn)訓(xùn)LossControl,inCaseofanAccident:InstallaPayPhone??損失控制制，有意意外事故故時：安安裝一個個付費電電話??InManyCases,LossControlIsNOTanOption在很多情情況下,損失控控制不是是實施方方案FirstStepforErrorProofingOptions防錯的第第一個步步驟DecidetheLevelofErrorProofingNeeded需要決定定防錯的的水平Eliminate,If排除，如如果SeverityIsHigh嚴重度高高PotentialforOccurrenceIsVeryHigh發(fā)生的可可能性很很大DetectionIsImpossible檢測是不不可能的的CostofEliminatingisLow排除成本本低Prevent,IfDesignIsCompleted,and防止，如如果設(shè)計計完成SeverityIsLow嚴肅性較較低RPNIsLowRPM低AttemptDetectioninMostOtherCasesofPotentialforDefects對其他潛潛在缺陷陷進行檢檢測BasedonPriority以優(yōu)先權(quán)權(quán)為基礎(chǔ)礎(chǔ)OpportunitiesforErrorProofing防錯的良良機消除預(yù)防檢測損失控制制產(chǎn)品設(shè)計計工工藝/設(shè)設(shè)備設(shè)計計車間措施施其其他質(zhì)質(zhì)量保證證措施ErrorProofingDecisionDiagram防錯決策策圖表PotentialError潛在的錯錯誤DefectFreeProduct無缺陷產(chǎn)產(chǎn)品ErrorsEliminated排除錯誤誤PreventErrorfromOccurring防止錯誤誤發(fā)生EliminateDuringProduct/ProcessDesign在產(chǎn)品/過程設(shè)設(shè)計中消消除錯誤誤DetecttheDefect發(fā)現(xiàn)缺陷DefectDetected缺陷檢測DefectPrevented缺陷防止DesignLossControlIntheProduct在產(chǎn)品中設(shè)計計損失控制DefectHasSeriousConsequences缺陷導(dǎo)致嚴重重結(jié)果NoNoNoNo無Yes有YesYes有YesDevelopLossControlProcedure開發(fā)損失控制制程序KeyPointsforElimination錯誤排除的關(guān)關(guān)鍵點LargestPotentialDuringDesign設(shè)計中中的巨巨大潛潛能EliminatebyDesigningOutActivitiesWithPotentialforErrors對潛在在的錯錯誤設(shè)設(shè)計活活動,進行行排除除CostEffectiveIfAddressedBeforeFinalizingtheDesigns(Product,Process,Equipment)設(shè)計定定案之之前（（產(chǎn)品品，程程序，，器材材）計計算成成本效效用MostCostEffectiveMethodofAll大多數(shù)數(shù)成本本效用用方法法SixSigmaQualityCanBeAchievedOnlyWithExtensiveElimination只有完完成大大范圍圍消除除措施施后才才可以以完成成6SigmaMotorolaMandatesAllProcessesforaNewProducttoBeSixSigmaCapable摩托羅羅拉要要求所所有產(chǎn)產(chǎn)品工工藝都都可以以使用用6Sigma.OnceEliminated,NothingElseisRequired一旦消消除,就不不需要要其他他的了了ErrorElimination&Symmetry排除錯錯誤和和對稱稱L1L2L1L1MakeThemAsymmetric使其不不均勻勻分布布MakeThemCompletelySymmetric使其完完全均均勻分分布PartiallySymmetricParts部分均均衡件件OR或ErrorElimination&Dimensioning排除防防錯和和決定定錯誤誤大小小WhichisBetter?哪一個個最好好？AskWhatisImportantandHowItShouldbeMeasured什么是是重要要，應(yīng)應(yīng)怎樣樣測量量ToEliminateModifyorRedesign?通過修修改或或重新新設(shè)計計排除除錯誤誤?SomeDefectscanbeRemovedbyModifications許多缺缺陷都都可以以通過過修改改排除除OthersMayNeedRedesign其他許許多需需要重重新設(shè)設(shè)計KeyPointsforPrevention預(yù)防的的關(guān)鍵鍵點EliminationIsBestWaytoPrevent排除除是是最最好好的的預(yù)預(yù)防防方方法法RobustDesign精力力充充沛沛的的設(shè)設(shè)計計DesigntoTolerateUnavoidableVariations對不不可可避避免免的的變變化化進進行行設(shè)設(shè)計計EnsuresAcceptableProductsforWiderVariations確保?？煽梢砸越咏邮苁艿牡漠a(chǎn)產(chǎn)品品允允許許有有較較大大的的變變化化DesignSoThatErrorsCannotBeMade設(shè)計,以以免會產(chǎn)產(chǎn)生錯誤誤DesignProducts,Processes,Equipment,FixturesThatWillPreventWrongPartsFromBeingUsed(PokaYokeDevices)設(shè)計(PokaYoke裝置)產(chǎn)產(chǎn)品,工工藝,設(shè)設(shè)備,卡卡具等可可以防止止錯誤的的裝置.Procedures,Training,DocumentationThatHelpPreventErrors防止錯誤誤的程序序,培訓(xùn)訓(xùn)文件等等ErrorProofDocumentGeneratingProcesses-ThatWillPreventManyDefectsFromReachingtheCustomer防止錯誤誤的文件件-阻止止太多缺缺陷到達達客戶.Drawings,etc.圖紙等ReturnUnacceptableProductBacktothe““Supplier”把不合格格件返回回供應(yīng)商商.InstitutionalizePreventionMindset結(jié)構(gòu)化預(yù)預(yù)防措施施ConceptsforPreventionontheShopFloor車間預(yù)防防的理念念A(yù)lwaysProvideAidforCounting為計算提提供依據(jù)據(jù)HelpIndicateSelectionofParts幫助進行行零件選選擇ColorCoding,LightedIndicators彩色碼,彩燈指指示器ProvideOnlyWhatIsNeeded,PreventAccesstoOthers僅提供供所需需要的的,阻阻止進進入其其他部部分VerifyMachineSettingsThatControlCriticalDimensionsBeforeMachining驗證設(shè)備裝裝置等,可可以在加工工前控制標標準尺寸EmployTPMforEquipmentandDies設(shè)備及模具具可以實施施TPMImplementMechanismsThatHelptheOperators實施操作者者易使用的的機械裝置置BarCoding,CheckLists,GraphicWorkInstructions條碼,檢驗驗列表,圖圖表化的操操作說明InvolvetheOperators包括操作者者CarefullyDispositionRejectedParts仔細處理不不合格件AvoidRepetitive,Monotonous,HazardousTasks避免重復(fù)，，單調(diào)，危危險的任務(wù)務(wù)Standardize標準化DesignedtoPreventDefects預(yù)防防缺缺點點的的設(shè)設(shè)計計SensorstoDifferentiateIdenticalParts區(qū)別別可可互互換換零零件件的的傳傳感感器器L1L2AlmostIdenticalParts幾乎乎是是可可互互換換零零件件CoordinatedLightSensorsDifferentiatetoPreventErrors用燈燈傳傳感感器器來來區(qū)區(qū)分分預(yù)預(yù)防防錯錯誤誤DetectPresenceorAbsencetoPreventDefects使用用存存在在或或不不存存在在缺缺陷陷的的方方法法預(yù)預(yù)防防缺缺陷陷VerifyPresenceofScrewstoPreventAssembliesWithoutScrews確定定螺螺絲絲的的存存在在來來預(yù)預(yù)防防裝裝配配忘忘記記螺螺絲絲DetectSplicetoHelpDiscardtheSection探測接口幫助助廢棄某部分分VerifyLiquidLeveltoPreventShippingUnfilledBottle確認液體水平平,來預(yù)防未未裝滿瓶子運運走VariousTypesofCounterstoPreventDefects各種型號的計計算器來防止止缺陷2134BreakingtheLightCurtain斷掉燈的線路路LightReflectingSensors燈光反映感應(yīng)應(yīng)器InductanceSensors自感應(yīng)器KeyPointsforDetection探測的關(guān)鍵點點PokaYokeDevicesCanAddressMostoftheManufacturingDefectsPokaYoke裝置可以探測測大多數(shù)生產(chǎn)產(chǎn)缺陷的位置置DetectionTakesCareofWhatWasNotPreventedUpstream,orintheCurrentProcess可以探測到以以前沒有預(yù)防防住的點,或或現(xiàn)場工藝中中的錯誤DetectionShouldTarget“Direct”Parameter,Examples:探測需定位正正確的參數(shù),例如:MeasurePressureUndertheNut,NottheTorque測量螺母下面面的壓力,而而不是扭矩下下面的壓力MeasureWeldStrength,NotWeldingCurrent測量焊接件的的強度,而不不是焊接件的的電流DetectionMustBeClosetotheProcess探測必須接近近工藝RightBeforeforIncomingParts進件以前前正確RightAfterforCompletedActivity完成活動動以后正正確DetectionShouldRejectUnacceptableParts&ProvideImmediatefeedback(PokaYokeDevices)探測應(yīng)拒拒收不合合格件&立即提提供反饋饋(PokaYoke裝置)DetectionShouldBeReliable,CertifiableandMonitored探測須是是可靠的的,有保保證的,可以監(jiān)監(jiān)控的.MeasureDimensions(Go,NoGo)toDetectDefects測量尺寸寸(通止止規(guī))來來探測缺缺陷MeasureSheetThickness測量鋼板板厚度MeasureDiameter測量直徑徑MeasureSheetWidth測量鋼板板寬度DetectDifferentFeatures探測不同同的特性性DetectPickupofaSheet探測鋼板板位置DetectPresenceofFeatures探測特性性的存在在性DetectColorAccuracy探測顏色色精確性性DetectionUsingContact使用接觸觸探測RememberThisPart?是否記得得這個零零件?WhattoDoIfItCannotberedesigned?如果不能能重新設(shè)設(shè)計怎么么做FixtureDesignedtoDetectIncorrectOrientation設(shè)計卡具具檢測位位置正確確性DetectingDimensionUsingContact用接觸法法測定尺尺寸Accept可接受件Reject廢棄件GoodPart合格件BadPart不合格件件KeyPointsforLossControl損失控制制的關(guān)鍵鍵點Design,IntheProduct,AvoidanceofCatastrophicResults在產(chǎn)品設(shè)設(shè)計中避避免大的的損失SeveralBackupSystemsinAircraft,EjectionSeats,Parachute航行器,排除座座,降落落傘的備備份系統(tǒng)統(tǒng)Airbag安全氣袋袋LimitedClinicalTrialsonHumansofNewDrugs新藥物對對人進行行臨床實實驗FinalFunctionalTests,BeforeShipping運輸前的的最后功功能實驗驗NothingDetectedonIndividualParts不對單獨獨件進行行檢驗ScheduledMaintenanceChecksofMissionCriticalItems對于關(guān)鍵鍵項目任任務(wù)提供供定期維維修ShouldBetheLastResort對關(guān)鍵物物品進行行定期維維修檢驗驗,應(yīng)該該有檢驗驗報告DriversDoGetinAccidents,SaveThemWithAirbags司機遇到到交通事事故時,安全氣氣囊可以以對他們們進行保保護NOTDesignUnsafeCars不要設(shè)計計不安全全的汽車車EarlyCommunication,RecallsAreExtremelyImportantforLossControl早期交流流,招回回對損失失控制是是非常重重要的TraditionalQualityControlVersusErrorProofing傳統(tǒng)的質(zhì)質(zhì)量控制制與防錯錯進行比比較Op1Op2Op3Op4Test/Inspect檢驗/檢測Scrap廢品Accept接受Op1Op2Op3Op4Verify確定確認Verify確定確認Verify確定確認Feedback反饋Feedback反饋Feedback反饋Traditional,CompleteProduct&TestorInspect傳統(tǒng),完完成產(chǎn)品品實驗及及檢驗ErrorProofing,VerifyAfterEveryOperation&反饋每一序后后以及反反饋后進進行防錯錯確認DetectionVersusPrevention探測與預(yù)預(yù)防的比比較TraditionalQualityControlVersusErrorProofing傳統(tǒng)的質(zhì)質(zhì)量控制制與防錯錯進行比比較TraditionalQUALITYCONTROL傳統(tǒng)質(zhì)量量控制InspectorTestFunctionalitytoDetectDefectiveproduct(FinalProductDefect)功能檢測測及實驗驗來探測測缺陷產(chǎn)產(chǎn)品(最最后產(chǎn)品品缺陷)TheTestProduces““Accept”““Reject”Judgement通過實驗選選出合格件件與不合格格件TestorInspectAfterSeveralOperations幾序以后進進行實驗與與檢測DifficulttoPinpointCauseoftheDefect精確找出缺缺陷原因很很困難NoDirectfeedbacktotheOffendingOperation對于不穩(wěn)定定序沒有直直接反饋LongDelayBetweenError&DiscoveryofDefect錯誤產(chǎn)生與與發(fā)現(xiàn)缺陷陷之間拖延延太長ErrorProofing防錯VerifySpecificCharacteri-stic&PreventErrororDetectInter-processDefect確定具體的的防錯以及及工藝缺陷陷預(yù)防Verification““Catches”DefectiveComponent確認捕捉缺缺陷件VerificationIsImmediate立即確認RelationofDefect&ErrorIsAlreadyKnown缺陷與錯誤誤之間的關(guān)關(guān)系已知道道FeedbackIsImmediate立即反饋NoDelayinDefectDiscovery不能拖延缺缺陷件的發(fā)發(fā)現(xiàn)TraditionalQualityControlVersusErrorProofing-Results傳統(tǒng)的質(zhì)量量控制與防防錯進行比比較-結(jié)果果Op1Op2Op3Op4Test/Inspect實驗/檢測Scrap廢品Accept合格Op1Op2Op3Op4Verify確定確認Verify確定確認Verify確定確認Feedback反饋Feedback反饋Feedback反饋Traditional,CompleteProduct&TestorInspect傳統(tǒng),完成成產(chǎn)品實驗驗及檢驗ErrorProofing,Verify確定AfterEveryOperation&反饋每一序后以以及反饋后后進行防錯錯確認99.6%99.9%99.9%99.9%99.9%99.9%99.9%99.9%99.9%99.9%TypesofChecks/Verifications檢驗/確認認類型