防錯技術(shù)培訓和案例

IntroductiontoPokaYokePoka-yokeandJidoka:ContinuousimprovementtoZeroQualityControl2022/11/2 >1QualityandHumanError“Toerrishuman…”…AlexanderPopeHumanbeingsmakemistakes,humanbeingssometimesforget.Ifyourelyonahumanbeingtoproducequalityproductandnotmakeamistakeornotforgetsometimes…..Thenyoureallydonotcaretomakeaqualityproduct.ADDRESSQUALITYISSUESTHROUGHTHEPROCESS.2022/11/2

IntroductiontoPokaYoke>>2EvolutionofKey“Lean”Concepts=ConceptsrelatedtoPoka-yokeShigeoShingoZeroQualityControlconcept:1977“ZeroDefects”concept:1975SMEDmethodologyformalized:1969InspiredbyToyota“Foolproofing”measures,developsmethodologytoapplytechniquestosourceinspection:19651965:Kanban,externalsuppliers1962:Kanban,companywide,internalShigeoShingobeginsconsulting1955:WaterspiderconceptrelationshipwithToyota:19541953:“Supermarket”systems1953:Workcellsin“U”shapedlayoutsSet-upreduction:internal&external,1950:Foolproofingtechniquesandtheconceptof“autonomation”(Poka-yoke)1ststagesofSMED:19501950:Andon,visualcontrol1950:Multi(3-4)machinehandling,rectangularor“U”shapedlayout1948:Pull:Withrawalbysubsequentprocesses1947:Dualmachinehandling,“L”shapedlayout1945:JustInTime2022/11/2

Toyota&TaichiiOhnoIntroductiontoPokaYoke>>3ContentsIntroductiontoPoka-yokeandtypesofinspectionsystemsPoka-yokeSystemsPoka-yokeMethodsCommonMistakeProofingDevicesPoka-yokeexercisesShingoQuizIntroductiontoPokaYoke2022/11/2>>42022/11/2

Poka-yokeandJidoka:Simple&ClearPoka-yoke:Poka-yokepreventsdefectsfrombeingmadeJidoka:PreventsdefectsfrombeingpassedontothenextstepintheprocessHumanInspectionHumanInterventionMistakeProofingwithmachineassistToll-gateIn-ProcessVisualInspectionPoka-yokeInspectionInspection&EvolutiontowardZeroJidokaQualityControl-atFinishedFinalInspectionmayThebeginningofOperatorTimededicatedGoodsdecrease,operatorsautonomation-toContinuousortheendofmaydorequiredsignificantdefectImprovementmainprocessesprocessinspectionsreductionsIntroductiontoPokaYoke55ThreeBasicTypesofInspection?Willnotreducedefects2022/11/2

TherearethreebasictypesofinspectiontechniquesJudgmentInspection–Human,visual,possiblymeasured–OnlydiscoversdefectsafterproductionInformativeInspection–StatisticalQualityControl:flowcharts,controlcharts–Theoreticalsamplingtechniques–Selfcheckinspection,SuccessiveInspection–InspectsproductstohelpcontroltheprocessSourceInspection–Processfocused–Tocorrectoperatingconditions–Rootcausesareeliminatedorcorrected–BeforeproductionoccursIntroductiontoPokaYoke>>62022/11/2

AShortStoryYamadaElectric,Nagoya,JapanThePlantmanager:“Oneoftheoperationswedoinvolvestheassemblyofanextremelysimplepush-buttondevicethatwedelivertoourparentcompany,MatsushitaElectric.Thedeviceiscomposedoftwobuttons,andonbuttonandanoffbutton,undereachofwhichwehavetoencloseasmallspring.Sometimes,though,oneofourworkersforgetstoputinaspring.WhenMatsushitaelectricdiscoversaswitchwithoutaspring,wehavetosendaninspectorallthewaytoKyushatocheckeveryswitchthatwasdelivered.Thisisarealpainintheneck,sowheneverithappens,wetellworkerstobeparticularlycarefulandforawhilethingsimproveabit.Thesamethinghappensagainbeforelong,though,andthesechronicdefectsaregettingtobeanuisance.Matsushitagetsmadatuseverytimeformakingmistakesinsuchasimpleoperation,andIrecentlyhadtogotoKyushamyselftoapologize.Isthereanythingwecandotokeepthesedefectsfromhappening?”IntroductiontoPokaYoke>>7Question:Haveyoueverforgottenanything?2022/11/2

AShortStoryYamadaElectric,Nagoya,JapanTheConsultantandthePlantManager:“Whatdoesitmeanforahumanbeingto‘forget’something?”PM: Theplantmanagerlookedpuzzled…“To‘forget’means…well…itjustmeansto‘forget’something,doesn’tit?”WhentheConsultantaskedthePlantManagertoexplain,hewasunabletoanswer.Sohesuggestedtohimthattherewerereallytwokindsofforgetting.Thefirstinvolvessimplyforgettingsomething.Sincepeoplearenotperfect,theywill,onrareoccasions,simplyforgetsomething.Itisnotintentional,itjusthappens.“Thesecondtypeofforgetting,involvesforgettingthatonehasforgotten.Weareallfamiliarwiththiskindofforgetting.Itisthereason,forexample,thatwemakechecklistsforourselves.Youcanapplythesamethingtothisoperation,ratherthanthinkingthatyourpeopleshouldassembleswitchesperfectly,everytime,youshouldrecognizethatbeinghuman,theywill,onrareoccasionsforgetthings.Whynottaketheideaofthechecklistandincorporateitintoyourprocess.”IntroductiontoPokaYoke>>8AShortStoryYamadaElectric,Nagoya,JapanBoxwithButtonsSprings

TheCurrentState:Theoperatorassemblestwoswitchesatatime,placesthefinishedswitchesintoaboxthatholdsonehundred.Beforeshipping,aQCinspectorpullsasampleoutofeverybox.ButtonsBoxwith2022/11/2

TheSolutions:1.Theoperatorassemblestwoswitchesatatime,placesthefinishedswitchesintoarackthatholdonlysix,aftercompletingsix,pusheseachbuttononeachofthesixtochecktoseeifthespringisthere.Afterpushingthebuttons,theoperatorpacksintothebox.IntroductiontoPokaYoke>>9AShortStoryYamadaElectric,Nagoya,JapanTheSolutions:2.Inthefirstmotion,anoperatorinsertstwospringsintheswitchthenmovesthemtooperatortwo.BoxwithButtonsSpringsOperatortwoinspectsthatthespringisinplace,thenplacesthecoverontheswitch,placesthefinishedswitchesintoaboxthatholdsonehundred.Beforeshipping,aQCinspectorpullsasampleoutofeverybox.Theoperatorhasasmallbowlinfrontofher.Inherfirstmotionshetakestwospringsfromthebox,placestheminaBoxwithButtonsSprings

dish.Inhersecondmotion,sheinsertsthespringandthenthebuttonsareinstalled.Ifanyspringremainedonthedishafterassembly,theworkerrealizedthataspringhadbeenleftout,andtheassemblywascorrected.2022/11/2

IntroductiontoPokaYoke>10>10BoxwithSpringsButtons2022/11/2

AShortStoryYamadaElectric,Nagoya,JapanTheSolutions:Thebuttonisdesignedsothatitcannotbeinstalledunlessthespringispresentintheswitch.Operatorinstallstwosprings.Operatorplacesbuttononswitch.Operatorpacks.Boxisreadyforshipment.IntroductiontoPokaYoke>11>11SevenGuidelinesforPoka-yoke*QualityProcesses-Design“Robust”qualityprocessestoachievezerodefects.UtilizeaTeamEnvironment-leveragetheteamsknowledge,experiencetoenhancetheimprovementefforts.EliminationofErrors-Utilizearobustproblemsolvingmethodologytodrivedefectstowardszero.Eliminatethe“RootCause”ofTheErrors-Usethe5Why’sand2H’sapproachDoItRightTheFirstTime-Utilizingresourcestoperformfunctionscorrectlythe“first”time.EliminateNon-ValueAddedDecisions-Don’tmakeexcuses-justdoit!ImplementanIncrementalContinualImprovementApproachimplementimprovementactionsimmediatelyfocusonincrementalimprovementseffortsdonothavetoresultina100%improvementimmediately.IntroductiontoPokaYoke2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

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12> 12PokayokePoke-yokeandPointofOriginInspections(ProactiveApproach):AfullyimplementedzerodefectsystemrequiresPokayokeusageatorbeforetheinspectionpointsduringtheprocess.Pokayokewillcatchtheerrorsbeforeadefectivepartismanufactured100%ofthetime.*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellenceIntroductiontoPokaYoke>13>13JidokaJidokaandInformativeInspection(ReactiveApproach):Checkoccursimmediatelyaftertheprocessstep.100%foolproofchecking(nointerpretationbyoperatorincontrol/checking…)100%ofTimeAlthoughnotaseffectiveastheSourceinspectionapproach,thismethodologyisEffectiveinpreventingdefectsfrombeingpassedtonextprocess.Itismoreeffectivethanstatisticalsamplinganddoesprovidefeedbackinreducingdefects.2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>14>14PokayokeSystemsGoverntheProcessTwoPokaYokeSystemapproachesareutilizedinmanufacturingwhichleadtosuccessfulzerodefectsystems:ControlApproachShutsdowntheprocesswhenanerroroccurs.Keepsthe“suspect”partinplacewhenanoperationis incomplete.WarningApproachSignalstheoperatortostoptheprocessandcorrectthe problem.*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellenceIntroductiontoPokaYoke>15>15ControlversusWarningCONTROLAPPROACHTakeshumanelementoutoftheequation;doesnotdependonanoperatororassembler.Hasahighcapabilityofachievingzerodefects.Machinestopswhenanirregularityisdetected

WARNINGAPPROACHSometimesanautomaticshutoffsystemisnotanoption.Awarningoralarmsystemcanbeusedtogetanoperatorsattention.Belowleftisanexampleofanalarmsystemusingdials,lightsandsoundstobringattentiontotheproblem.Colorcodingisalsoaneffectivenonautomaticoption.2022/11/2

IntroductiontoPokaYoke>16>16Poka-yokeandJidokaInspectionMethodSettingFunctionRegulativeFunctionSourceInspectionContactMethodPoka-yoke-ProactiveControlMethodStopstheProcessInformativeInspectionConstantValueMethod(self)Countspartsoroperationsteps.Jidoka-ReactiveWarningMethodInformativeInspectionMotion-SequenceMethodAlarmorLighttellsoperatorto(successive)Jidoka-Reactivetakeaction(eg:stopmachine)2022/11/2

IntroductiontoPokaYoke>17>17CommonMistakeproofingDevicesGuidePinsBlinkinglightsandalarmsLimitswitchesProximityswitchesCountersChecklistsIntroductiontoPokaYoke*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellence>18>18MethodsforUsingPokayokePokayokesystemsconsistofthreeprimarymethods:ContactCountingMotion-SequenceEachmethodcanbeusedinacontrolsystemorawarningsystem.Eachmethodusesadifferentprocesspreventionapproachfordealingwithirregularities.2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>19>19ContactMethodMissingcylinder;pistonfullyextended,alarmsoundsCylinderpresent

Acontactmethodfunctionsbydetectingwhetherasensingdevicemakescontactwithapartorobjectwithintheprocess.Anexampleofaphysicalcontactmethodislimitswitchesthatarepressedwhencylindersaredrivenintoapiston.Theswitchesareconnectedtopistonsthatholdthepartinplace.Inthisexample,acylinderismissingandthepartisnotreleasedtothenextprocess.Cannotproceedtonextstep.ContactMethodusinglimitswitchesidentifiesmissingcylinder.2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>20>20PhysicalContactDevicesToggleSwitchesLimitSwitches*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>21>21EnergyContactDevicesLightTransmitter Receiver

Photoelectricswitchescanbeusedwithobjectsthataretranslucentortransparentdependingupontheneed.Transmissionmethod:twounits,onetotransmitlight,theothertoreceive.Reflectingmethod:PEsensorrespondstolightreflectedfromobjecttodetectpresence.Ifobjectbreaksthetransmission,themachineissignaledtoshutdown.Object*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>22>22ContactDevice? Anexampleofacontactdeviceusingalimitswitch.Inthiscasetheswitchmakescontactwithametalbarbsensingit’spresence.Ifnocontactismadetheprocesswillshutdown.*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>23>23ContactMethodsDonothavetobehightech!Passivedevicesaresometimesthebestmethod.ThesecanbeassimpleasguidepinsorblocksthatdonotallowpartstobeseatedinthewrongpositionpriortoprocessingTakeadvantageofpartsdesignedwithanunevenshape!Aworkpiecewithaholeabumporanunevenendisaperfectcandidateforapassivejig.Thismethodsignalstotheoperatorrightawaythatthepartisnotinproperposition.*Source:Superfactory,2022/11/22003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>24>24CountingMethodUsedwhenafixednumberofoperationsarerequiredwithinaprocess,orwhenaproducthasafixednumberofpartsthatareattachedtoit.Asensorcountsthenumberoftimesapartisusedoraprocessiscompletedandreleasesthepartonlywhentherightcountisreached.Anotherapproachistocountthenumberofpartsorcomponentsrequiredtocompleteanoperationinadvance.Ifoperatorsfindpartsleftoverusingthismethod,theywillknowthatsomethinghasbeenomittedfromtheprocess.*Source:Superfactory,2022/11/22003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>25>25Motion-SequenceMethodThethirdpokayokemethodusessensorstodetermineifamotionorastepinaprocesshasoccurred.Ifthestephasnotoccurredorhasoccurredoutofsequence,thesensorsignalsatimerorotherdevicetostopthemachineandsignaltheoperator.Thismethodusessensorsandphoto-electricdevicesconnectedtoatimer.Ifmovementdoesnotoccurwhenrequired,theswitchsignalstostoptheprocessorwarntheoperator.*Source:Superfactory,2022/11/22003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>26>261.什么是傳統(tǒng)機械按鍵設計？傳統(tǒng)的機械按鍵設計是需要手動按壓按鍵觸動PCBA上的開關(guān)按鍵來實現(xiàn)功能的一種設計方式。傳統(tǒng)機械按鍵結(jié)構(gòu)層圖：傳統(tǒng)機械按鍵設計要點：1.合理的選擇按鍵的類型，盡量選擇平頭類的按鍵，以防按鍵下陷。按鍵 PCBA 2.開關(guān)按鍵和塑膠按鍵設計間隙建議留0.05~0.1mm，以防按鍵死鍵。3.要考慮成型工藝，合理計算累積公差，以防按鍵手感不良。開關(guān)鍵IntroductiontoPokaYoke27Motion-SequenceMethodInordertohelpoperatorsselecttherightpartsfortherightstepinaprocessthe“sequencing”aspectofthemotion-stepmethodisused.Thisisespeciallyhelpfulwhenusingmultiplepartsthataresimilarinsizeandshape.Inthisexample,eachstepofthemachinecycleiswiredtoanindicatorboardandatimer.Ifeachcycleofthemachineisnotperformedwithintherequired“time”and“sequence”,theindicatorlightforthatstepwillbeturnedonandthemachinewillstop.Machine*Source:Superfactory,2022/11/22003.Module6,FundamentalsofManufacturingExcellence

IndicatorBoardIntroductiontoPokaYokeTypesofSensingDevicesSensingdevicesthataretraditionallyusedinpokayokesystemscanbedividedintothreecategories:PhysicalcontactdevicesEnergysensingdevicesWarningSensorsEachcategoryofsensorsincludesabroadrangeofdevicesthatcanbeuseddependingontheprocess.*Source:2022/11/2Superfactory,003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>29>29Devices:PhysicalContactSensorsThesedevicesworkbyphysicallytouchingsomething.Thiscanbeamachinepartoranactualpiecebeingmanufactured.Inmostcasesthesedevicessendanelectronicsignalwhentheyaretouched.Dependingontheprocess,thissignalcanshutdowntheoperationorgiveanoperatorawarningsignal.2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>30>30Device:TouchSwitchMethod:ContactUsedtophysicallydetectthepresenceorabsenceofanobjectoritem-preventsmissingparts.Usedtophysicallydetecttheheightofapartordimension.*Source:2022/11/2Superfactory,2003.Module6,FundamentalsofManufacturingExcellenceIntroductiontoPokaYoke>31>31Devices:EnergySensorsThesedevicesworkbyusingenergytodetectwhetherornotandefecthasoccurred.VibrationPhotoelectric2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellenceFiberopticIntroductiontoPokaYoke>32>32WarningSensorsWarningsensorssignaltheoperatorthatthereisaproblem.Thesesensorsusecolors,alarms,lightstogettheworkersattention!ColorCode?Lights:Thesesensorsmaybeusedinconjunctionwithacontactorenergysensortogettheoperatorsattention.LightsLightsconnectedtoMicroswitches&timers*2022/11/2Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke3RulesofPOKAYOKEDon’twaitfortheperfectPOKAYOKE.Doitnow!IfyourPOKAYOKEideahasbetterthan50%chancetosucceed…Doit!Doitnow….improvelater!2022/11/2*Source:Superfactory,2003.Module6,FundamentalsofManufacturingExcellence

IntroductiontoPokaYoke>34>34PokaYokeExercise#1-ProblemMatsushitaElectric:IndustrialWashingMachineDivisionCorrectwaterleveliscriticaltothepackage-sealingmachine.Operatorvisuallycheckswaterlevel4Xpershift.Instancesofinadequatewaterlevelshaveoccurred.ValveWaterlineAcceptablewaterlevel2022/11/2

Whatwouldyoudo?IntroductiontoPokaYoke>35>35PokaYokeExercise#1-SolutionMatsushitaElectric:IndustrialWashingMachineDivisionInadequatewatervolumeactivatesawaterlevelsensorandavalveopensautomaticallytosupplywater.Approximatecost:$150WaterlineWater-levelsensorsValve2022/11/2

IntroductiontoPokaYoke>36>36PokaYokeExercise2-ProblemAsahiNationalLightingCompanyTheupperandlower“boxers”stapletheboxclosed.Occasionallythebottomstapler“misses”.Sincecasescontinuetomovealongtheline,itisespeciallydifficulttoverifythepresenceofastapleonthebottomofthebox.Whatwouldyoudo?2022/11/2

IntroductiontoPokaYoke>37>37PokaYokeExercise2-SolutionAsahiNationalLightingCompanyAsensortodetectstapleswasmountedattherearofthepackagingmachine.Thissensor,linkedtoacounter,verifiesthenumberofstaplesandsendsasignaltothe“stopper”tostopthecasesifastapleismissed.2022/11/2

IntroductiontoPokaYoke>38>38PokaYokeExercise3-ProblemAsakawaAutoBodyIndustriesInatwostepprocess,workerswouldfirstdrillholesinaboardset,thentaketheboardsetandspotweldit.Occasionallytheoperatorswouldforgettodrillalloftheholesrequired.Afterspotwelding,thepiececouldnotbereworkedifitwasmissingholes.Multi-spotMachine DrillFlow2022/11/2

Whatwouldyoudo?IntroductiontoPokaYoke>39>39PokaYokeExercise3-SolutionAsakawaAutoBodyIndustriesThewelderanddrillwerelinked.Simpleholesensorswereinstalledonthedrillmachine.Thespotwelderwouldnotoperateunlessallholesweredetected.Multi-spotMachineFlow2022/11/2

IntroductiontoPokaYoke>40>402022/11/2Multi-spotMachine DrillMulti-spotMachineIntroductiontoPokaYoke>41>412022/11/2IntroductiontoPokaYoke>42>42ShigeoShingoZeroQualityControl:SourceInspectionandthePoka-yokeSystem2022/11/2

IntroductiontoPokaYoke>43>432022/11/2

ShingoQuizWhichofthefollowingisnotoneoftheinspectiontechniquesidentifiedbyShingo:SourceInformativeStatisticalJudgmentJudgmentInspection:isaveryeffectiveinspectiontechniquereducesdefectratesdramaticallyusedsolelytodiscoverdefectsafterproductionshouldbeusedwheneverpossibleIntroductiontoPokaYoke>442022/11/2

ShingoQuizAsettingfunction:isaveryeffectiveinspectiontechniquesignalsthatadefecthasoccurredkeepsamachinefromoperatingwhendefectsarelikelytobeproducedisthelinkbetweeninspectionandtheregulatoryfunctionAregulatoryfunction:istheremedialactiontakenafteraprocessgoesout-of-controlsignalsthatadefecthasoccurredkeepsamachinefromoperatingwhendefectsarelikelytobeproducedBorCIntroductiontoPokaYoke>45>452022/11/2

ShingoQuizSourceInspection:reducesdefectratesdramaticallyusedsolelytosortoutdefectsafterproductionshouldbeavoidedbothA&BWhichisnotaninformativeinspectiontechnique:statisticalprocesscontrolacceptancesamplingsuccessive-checksself-checksIntroductiontoPokaYoke>46>462022/11/2

ShingoQuizThecorrectrankingofShingo'sinspectiontechniques(frombesttoworst)is:judgment,informative,sourcesource,judgment,informativeinformative,source,judgmentsource,informative,judgmentInformativeInspection:inspectsproductstohelpcontroltheprocessinspectsprocesstohelpcontroltheproductkeepsamachinefromoperatingwhendefectsarelikelytobeproducedshouldbeavoidedIntroductiontoPokaYoke>47>47ShingoQuizPoka-Yoke:replacesanyqualitysystemyouarecurrentlyusingcanreduceoreliminatehumanerrorcannotbeusedtoreduceprocessvarianceisonlyusedforsourceinspection2022/11/2IntroductiontoPokaYoke>48>48ShingoQuizShingoidentified3inspectiontechniques:judgement,informative,sourceIsusedsolelytodiscoverdefectsafterproduction.

WhichofthefollowingisnotoneoftheinspectiontechniquesidentifiedbyShingo:SourceInformativeStatisticalJudgmentJudgmentInspection:isaveryeffectiveinspectiontechniquereducesdefectratesdramaticallyusedsolelytodiscoverdefectsafterproductionshouldbeusedwheneverpossible2022/11/2

IntroductiontoPokaYoke>49>49ShingoQuizAsettingfunctiondetectswhentheinspectionoutcomeisnotacceptableandinvokestheregulatoryfunctionAregulatoryfunctionisanattention-gettingsignal(abuzzer,warninglightormachinestoppage)thatsomethingiswrong.Itcanindicateadefecthasjustbeenmade(inself-checks)orthatitisabouttobemade(insourceinspections).

Asettingfunction:isaveryeffectiveinspectiontechniquesignalsthatadefecthasoccurredkeepsamachinefromoperatingwhendefectsarelikelytobeproducedisthelinkbetweeninspectionandtheregulatoryfunctionAregulatoryfunction:istheremedialactiontakenafterapro