精益生产防错课件.ppt

1、1 2003 Eaton Corporation.All Rights Reserved.4/11/03Error Proofing防错防错2 2003 Eaton Corporation.All Rights Reserved.4/11/03Topics-Error Proofing TrainingDuration时间区间时间区间Start开始时间开始时间Error Proofing 防错防错Objective of the Training&Expectations0:158:00 AM培训的目标及预期目的0:158:00 AMWhat and Why or Error Proofing

2、-Exercise 11:008:15 AM什么是防错，为什么进行防错-练习11:008:15 AMCoffee Break中间休息中间休息0:159:15 AMApplication of Error Proofing-Overview Exercise 2 1:009:30 AM 2 防错应用-总体练习21:009:30 AMIdentify Opportunities for Errors&PFEMA,Exercise 31:0010:30 AM 识别防错及PFEMA良机,练习31:0010:30 AMError Proofing Options0:3011:30 AM 防错方案1:00

3、10:30 AMLunch Break 午休午休0:4512:00 PMError Proofing Options(continue)Exercise 41:0012:45 PM防错方案(续)练习41:0012:45 PMActivities 措施措施3 2003 Eaton Corporation.All Rights Reserved.4/11/03Topics主题主题4 Objectives of the Training4 培训的目的4 What and Why of Error Proofing4 什么是防错，怎样进行防错4 Application of Error Proofin

4、g4 防错应用4Identify Opportunities for Errors4防错时机的确定8Overview of Failure Mode and Effects Analysis(FMEA)8失效模式和效果分析总括4Error Proofing Options4防错的选择4Prevention&Detection Through Poka Yoke Devices4通过Poka Yoke进行预防与探测4 Move to The Next Level4 转入下一级4A Benchmark Within Eaton4伊顿内部标准4 Summary4 概要4 2003 Eaton Cor

5、poration.All Rights Reserved.4/11/03Objectives of the Training培训的目的培训的目的4Understand What Is Error Proofing and What It Can Do4了解什么是防错和防错能做什么4Understand the Principles of Error Proofing4了解防错的原理4Learn How to Apply Error Proofing to Products and Processes4了解怎样对产品及工艺过程应用防错4Learn About the Poka Yoke Devi

6、ces and Systems4了解Poka Yoke装置和系统4Learn the Process of Implementation and Continuous Improvements4了解实施防错的过程和持续改进的过程5 2003 Eaton Corporation.All Rights Reserved.4/11/03What Are Your Expectations?你们的期望是什么？你们的期望是什么？6 2003 Eaton Corporation.All Rights Reserved.4/11/03What and Why of Error Proofing什么是防错以及

7、为什么要防错什么是防错以及为什么要防错7 2003 Eaton Corporation.All Rights Reserved.4/11/03Definition定义定义Error Proofing Is a Systematic Approach for Anticipating and Detecting Potential Defects and Preventing Them From Reaching the Customer(Internal or External)防错是一种预测及探测潜在缺陷以及阻止缺陷影响客户的体系方法(内部防错和外部防错)8 2003 Eaton Corpo

8、ration.All Rights Reserved.4/11/03Error Proofing by Other Names以其他名称进行防错以其他名称进行防错4Fool Proofing防止愚蠢行为4Idiot Proofing防止白痴行为4Mistake Proofing防止错误行为4Fail Safing安全失效4Poka Yoke4Zero Quality Control(Zero Defects)4零质量控制（零缺陷）4Design for Manufacture and Assembly4制造和装配的设计Let Us Not Argue the Merits of These N

9、amesLet Us Decide What We Want to Achieve我们不要争论这些名称,让我们决定想要完成什么?Demoralizing Terms防错防错术语术语9 2003 Eaton Corporation.All Rights Reserved.4/11/03Characteristics of Error Proofing防错的特点防错的特点4 Proactive Identification and Prevention前期识别及预防4Prevent First首先进行防错4Do Not Allow Defect From Going Further4其次不准许缺陷

10、进一步发展4 Intentionally Designed,Not Happenstance4 设计错误,非偶然错误.4 At the Source-Close to the Origination 4 错误的来源_接近发源地.4 Inexpensive First 首先成本不高4 Transparent to the Operator 操作者很容易发现4 Absolutely Reliable 错误根源查找绝对准确A Means to Achieve Zero Defect Product一种达到0缺陷产品的方法10 2003 Eaton Corporation.All Rights Res

11、erved.4/11/034 Defects in Products Are the Imperfections(or Faults,or Flaws,or Blemishes,or Shortcomings,or Failings,or Deficiencies)4缺陷缺陷是指产品里的不完整性(或者故障,或者裂纹,或者瑕疵，或者短处，或者过失4，或者不足)4 Resulting From Errors4 错误产生的结果4 Errors Are Human Oversights(or Faults,or Blunders,or Boo-boos,or Slip-ups,or Inaccurac

12、ies or Miscalculations)That Cause Defects in Products4错误错误是人为疏忽(或者过错,或者失误,或者低级错误，或者失败，或者精度失误或者计算4 失误)，这些引起产品的缺陷。Defects and Errors 缺陷和错误缺陷和错误SO,Errors Cause Defective Products!所以,错误导致有缺陷的产品产生!11 2003 Eaton Corporation.All Rights Reserved.4/11/03Why Are Errors Made为什么会导致错误为什么会导致错误4 Any Product Is a R

13、esult of Numerous Decisions Made and Actions Taken by Human Beings,During:4 任何产品都可以在下述一系列人为行为中产生错误：4Product Design4产品设计4Process Design4过程设计4Equipment Design4设备设计4Component Fabrication Processes4零件加工过程4Product Assembly Processes4产品装配过程4Inspection Processes4检验过程4Paperwork Generation4程序行程过程4Etc.等等And H

14、uman Beings are Fallible or Imperfect人是容易犯错或不完美的12 2003 Eaton Corporation.All Rights Reserved.4/11/03SOME Examples of Defects属于缺陷的一些例子属于缺陷的一些例子4 Wrong or Inappropriate Material4 错误或不适合的材料4 Wrong or Non-functioning Components4 错误或者没有功能的零件4 Wrong Dimensions or Tolerances4 尺寸或公差错误4 Missing Components4

15、零件漏装4 Foreign Matters,Contamination4 杂质物质,污秽物4 Damaged Product or Components4 受损产品或零件4 Wrong Paperwork,or Wrong Product Shipped4 程序错误或者运输了错误的产品4 Non-functioning or Malfunctioning Product4 没有功能的产品或者是故障产品4 Wrong Shipping,or Wrong Billing4 运输错误或者是填单错误13 2003 Eaton Corporation.All Rights Reserved.4/11/0

16、3SOME Examples of Causes of Defects导致缺陷的一些例子导致缺陷的一些例子4 Poor Design Decisions4 设计比较乏味4 Omitted or Wrong Processing4 过程疏忽或过程错误4 Missing/Extra Parts or Wrong Parts4 漏装/多装了错误的零件4 Omitted or Wrong Adjustment/Testing 4 遗漏调整/测试或调整/测试过程错误4 Wrong Equipment Setup or Loss of Setup4 设备设置错误或没有进行设备设置4 Wrong Mater

17、ial,Components or Assemblies4 材料，零件或者装配错误4 Wrong Communication,Instructions,Procedures,or Methods4 错误的信息，指令，程序，或者方法4 Inexperience,Lack of Training,Wrong Training,Lack of Retraining4 缺乏经验，缺乏培训，培训错误，缺少再培训14 2003 Eaton Corporation.All Rights Reserved.4/11/03SOME Examples of Results of Defects缺陷导致的结果示例缺

18、陷导致的结果示例4 Malfunction or Non-functioning Product4 有故障或者缺乏机能的产品4 Inconvenience,Discomfort,Injury,Death4 麻烦，不便，伤害，死亡4 Delays,Cancellations4 延期，取消4 Financial Losses4 财政损失4Loss of Use or Productivity4效用或者生产力的缺乏4Damage to Customers Property4损害客户的利益4Liabilities and Law Suites4负债和法律问题4 Loss of Reputation a

19、nd Business4 名誉和业务受损15 2003 Eaton Corporation.All Rights Reserved.4/11/03SOME Causes of Human Errors导致人们犯错误的一些原因导致人们犯错误的一些原因4 Forgetfulness,Loss of Concentration,Lack of Attention or Diverted Attention4 健忘，不集中，缺乏注意力或者转移注意力4 Misunderstanding or Lack of Understanding4 误会或者缺乏理解4 Lack of or Improper Exp

20、erience/Training4 缺乏经验/培训或者不正确的经验/培训4 Lack of Standardization4 缺乏标准4 Intentional or Willful Error4 有意图的或者恶意的错误4 Wrong or Delayed Decision4 决定错误或拖延4 Limited or Lack of Sensory Capability(e.g.,Smell,Color,Touch)4 有限的或者没有感官能力（例如，嗅觉，色彩，触觉）4 Lack of Application of Common Sense4 缺乏运用常识判断的能力16 2003 Eaton C

21、orporation.All Rights Reserved.4/11/03Error Proofing in a Few Words预防错误的一些方法预防错误的一些方法“occurrence of defect was the result of some condition or action,and that it would be possible to eliminate defects entirely by pursuing the cause.The causes of defects lie in worker errors,and defects are the resul

22、ts of neglecting those errors.It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.”缺陷的产生是一些环境或者行为导致的结果，但是完全有可能通过查找原因排除缺陷。缺陷原因在于工人，缺陷是因为工人忽视错误而产生的。如果工人能及时的发现错误并且消除错误，就不会导致缺陷的产生。Shigeo Shingo17 2003 Eaton Corporation.All Rights Reserved.4/11/03

23、Why Error Proof?为什么防错？为什么防错？4 99.9%Error Free Could Result in 4 99.9%没有错误导致什么结果42,000,000 Documents Lost by IRS IRS缺少2，000，000档案416,000 Pieces of Mail Lost Every Day 每天丢失16，000邮件422,000 Wrongly Debited/Credited Checks Per Hour4每个小时都会发生22，000写错借方和贷方的支票41,314 Wrongly Connected Phone Calls Per Minute4每

24、个小时都会发生1，314起电话占线420,000 Incorrect Drug Prescriptions Per Year4每个小时都会发生20，000起用错药物的情况412 Newborn Babies Given to Wrong Parents412个小孩被父母抱错42 Unsafe Landings Every Day at OHare Airport4每天都会有2起飞机不安全着陆432,000 Missed Heartbeats Per Person Each Year4每年每个人都会有32，000Is 99.9%Good Enough?99.9%够不够好?18 2003 Eato

25、n Corporation.All Rights Reserved.4/11/03The Errors That Became Headlines错误变成头条错误变成头条4 Titanic Sinking4 泰坦尼克号的沉没4 Challenger Booster Rocket Seal Failure4 挑战者号火箭发射失败4 Mars Landing Module Crash4 火星升空失败坠毁4 Hubbell Telescope Reflector Error4 Hubbell望远镜反射误差4 Exxon Valdez Oil Spill4 Exxon Valdez 石油泄露4 Che

26、rnobyl Nuclear Power Plant Meltdown4 Chernobyl Nuclear Power 设备报废4 Release of Methyl Isocyanate(MIC)From Union Carbide Plant in Bhopal,India4 甲基异丙酮从Bhopal,India,MIC碳化物厂房泄露4 Three Mile Island Nuclear Plant 4 三英里小岛的核厂房4 Firestone Tires on Ford Explorer4 福特车上的耐火石探测器19 2003 Eaton Corporation.All Rights

27、Reserved.4/11/03Error Proofing and Lean防错及精益生产防错及精益生产4 Lean Insists on One Piece Flow4 精益生产强调单件流4If That One Piece Is Defective,Flow Is Disrupte4如果单件流有缺陷,流向就会被打断4 Lean Insists on Limited Inventory4 精益生产强调有限库存 If That Inventory Is Defective,the Lines Can Sto4如果库存有缺陷,线路就会停止4 Lean Means Eliminating Was

28、te4 精益是指消除浪费4Defects and Corrective Actions Are Wast4缺陷以及纠正措施是针对浪费4 Lean Requires That Equipment Is Ready When Needed and Functions Well As Long As Necessary4 精益生产要求当需要设备时,设备马上可以用,且功能完好4Error Proofing the Tools,Fixtures,Setups,Methods and Documents Ensures Equipment Effectiveness 4刀具,卡具,启动,方法以及文件等防错

29、以确保设备的有效性20 2003 Eaton Corporation.All Rights Reserved.4/11/03Error Proofing Examples in Everyday Life在每天生活中防错的一些例子在每天生活中防错的一些例子4Home家里4Automatic Shutoff Irons4全自动熨斗4Ground Fault Circuit Breakers for Bathroom or Outdoor Electric Circuits4浴室或室外电气线路的接地保护4Pilotless Gas Ranges and Hot Water Heaters4油量表以

30、及热水器4Child-Proof Caps on Medicine Bottles4药瓶上保护小孩安全的瓶盖4Retail零售4Tamper-Proof Packaging4锥型防错包装4Bar Coding at Checkou4检验时的条码4Office办公室4Spell Check in Word Processing Software在 Word 4word处理软件中进行拼写检查4Verifying“Do you want to delete?”When Press the“Delete”Buttonon Your Computer4当按删除按钮时电脑会询问你“要删除吗”?4Facto

31、ry工厂4Dual Palm Buttons and Other Guards on Machinery 4设备上使用两个按扭及其他保护装置4Bar Coding4条码4Lock-Out/Tag-Out 4锁紧/打开标签21 2003 Eaton Corporation.All Rights Reserved.4/11/03Error Proofing Exercise No.1防错练习的第一部分防错练习的第一部分4Form Teams of Two4两个一组4List As Many Examples of Error Proofing As You Can,From Everyday Li

32、fe4从你每天的生活中,列出你能作到的关于防错的许多例子410 Minutes410分钟22 2003 Eaton Corporation.All Rights Reserved.4/11/03Application of Error Proofing防错的应用防错的应用23 2003 Eaton Corporation.All Rights Reserved.4/11/03Essential Steps for Error Proofing防错的基本步骤防错的基本步骤4 Identify Opportunities for Errors(Critical Factors)4 识别防错的时机(

33、关键因素)4 Prioritize Potential Errors for Error Proofing4 对潜在的错误加以，区分进行防错4Absolutely Must Prevent the Defects4必须完全的防止错误4Provide Containment and Study Further4预防错误和深入研究4May Be Tolerated,Within Predefined Limits4在计划的范围内进行防错4 Identify Root Causes of the Errors4 识别错误根源4 Develop and Evaluate Error Proofing

34、Options 4 开发和评估防错方案4 Select and“Design”the Error Proofing System4 选择和设计防错系统4 Implement-Plan,Install,Document,Train,Monitor4 实施防错设计反错，安装防错,编制防错文件,培训,监控4 Periodically Assess the Performance and Improve4 对防错情况进行定期评审及改进24 2003 Eaton Corporation.All Rights Reserved.4/11/03Manufacturing Processes制造过程制造过程P

35、roduct Quality产品质量产品质量Process Design过程设计过程设计Product Design产品设计产品设计What is the Right Time to Error Proof?正确的防错时间是什么时间正确的防错时间是什么时间?100:110:11:1As Early As Possible及早发现及早发现25 2003 Eaton Corporation.All Rights Reserved.4/11/03Why Error Proof Early During New Product Development为什么在新产品开发期间防错为什么在新产品开发期间防错

36、Cost of“Fixing”the Defects“修理修理”缺陷的成本缺陷的成本Concept Development观念开发观念开发Preliminary Design初步设计初步设计Detailed Product Design详细的产品详细的产品设计设计Customer Support客户支持客户支持Industrialization产业化产业化Production生产生产Process Design过程设计过程设计Cost of“Fixing”设备的花费设备的花费Multiplies With Life Cycle Stages整个过程当中的多项防错整个过程当中的多项防错Stage

37、s of Product Life Cycle产品生命周期中各个阶段产品生命周期中各个阶段26 2003 Eaton Corporation.All Rights Reserved.4/11/03Why Error Proof Early During Processing在处理期间为什么要尽早防错在处理期间为什么要尽早防错Cost of“Fixing”the Defects设备成本失效设备成本失效Incoming Parts外协件外协件After Completing the Process过程完成之后过程完成之后At the End of the Line产品最终离产品最终离开生产线开生产

38、线After Delivery to Customer 交付给客户之交付给客户之后后Final Test最后检验最后检验Cost of“Fixing”Increases With Process Steps随着程序步骤增长修复错误成随着程序步骤增长修复错误成本增长本增长Steps of Product Processing产品处理的步骤产品处理的步骤Reject&Return 废弃件废弃件No Delay没有拖延没有拖延Reject&Scrap废弃件废弃件&废品废品Minor Delay稍微拖延稍微拖延Reject&Scrap/Rework废弃件废弃件&废品废品/返工返工RescheduleS

39、ome Delay进度稍有进度稍有拖延拖延Significant Rework/ScrapAdd to the Production ScheduleDelayed Deliveries重要的返工重要的返工/废品影响生产进度废品影响生产进度及产品交付及产品交付Warranty CostsAdministrative CostsLiabilitiesReputationMarket Share Loss担保担保成本及管理成本增加成本及管理成本增加,导导致市场份额损失致市场份额损失27 2003 Eaton Corporation.All Rights Reserved.4/11/03Error

40、Proofing Exercise No.2防错训练的第二部分防错训练的第二部分4 Form Teams of Two4 两个一组4 Discuss and Agree on One Example of Product Design or Manufacturing Process to Analyze4 讨论一个产品设计或制造工艺的例子,并进行分析4 Identify 4 鉴别4Error Proofing Implemented防错实施4Estimate Cost/Quality Impact消除成本/质量影响OR或者4Error Proofing Opportunities Misse

41、d丧失防错良机4Estimate the Cost/Quality Impact消除成本/质量影响4 List Lessons Learned学到的教训清单4 Prepare to Present to the Class准备到课堂上展示4 20 Minutes4 20分钟28 2003 Eaton Corporation.All Rights Reserved.4/11/03Identify Opportunities for Errors识别防错的时机识别防错的时机29 2003 Eaton Corporation.All Rights Reserved.4/11/03Methods fo

42、r Identifying Potential Errors识别潜在的防错方法识别潜在的防错方法4 Customer Demanded-Good Start4 消费者的需求-良好的开始4 Internal Quality Results Reactive4 内部质量成效-反应4 Past Experience-Not Completely Reliable4 以往经验-不完全可靠4 Customer 反馈-Too Late4 消费者的反馈-太迟4 Systematic Analyses to Identify Potential Errors4 识别潜在的错误需进行系统分析4Potential

43、 Failure Mode and Effects Analysis(FMEA)4潜在的失效模式及效果分析(FMEA)8Product FMEA 8产品FMEA8Process FMEA8过程FMEA30 2003 Eaton Corporation.All Rights Reserved.4/11/03Potential Failure Mode and Effects AnalysesPFMEA潜在的失效模式和潜在的失效模式和 效果分析效果分析Overview总揽31 2003 Eaton Corporation.All Rights Reserved.4/11/03Key Points

44、of FMEAFMEA的关键部分的关键部分4 FMEA Analyses Potential Failures4 FMEA分析潜在失效4 Fleas Have to Be Done by Multi-functional Teams4 Fleas应由多功能组执行4 Design FMEA Should Be Initiated Before or at the Concept Stage4 设计设计FMEA是在开始之前或者概念形成阶段4 Process FMEA Should Be Initiated Before or at the Feasibility Stage,Prior to To

45、oling or Equipment Finalization4 过程过程FMEA是在工装及设备调整好开始生产之前或者可研阶段4 FMEAs Should Be Continuously Updated,As Changes in Product&Process Designs Take Place 4 应该不断更新,比如FMEAs中的产品&过程设计 4FMEAs Are Living Documents 4FMEAs 是活的文件4FMEAs Are Never Ending Processes 4FMEAs 是永远都不会结束的工艺32 2003 Eaton Corporation.All R

46、ights Reserved.4/11/03FMEA Type and LevelsFMEA的类型和水平的类型和水平Design FMEA设计设计FMEAProcess FMEA过程过程FMEASubsystem子系统子系统Critical Features关键特性关键特性Components/Parts零件零件Subassemblies分装分装Workstations工作台工作台Operations加工操作加工操作33 2003 Eaton Corporation.All Rights Reserved.4/11/03FMEA No.Item/ProcessProcess responsib

47、ilityPage Part No./Drg.No.Key DatePrepared ByCore Team:FMEA Date(Orig)Item orProcessFunctionRequirementPotentialFailure ModePotential Effect(s)ofFailureSeverityClassPotential Cause(s)/Mechanism(s)ofFailureOccurCurrent ProcessControlsDetectR.P.N.RecommendedActionResponsibility&TargetCompletionDatePot

48、ential Failure Mode and Effects Analysis(FMEA)General Information(1)总说明总说明2345678101191234 2003 Eaton Corporation.All Rights Reserved.4/11/03FMEA Steps FMEA 的步骤的步骤Design FMEA设计设计FMEAGeneral Information-Details of the Product&FMEA 信息总说明-产品及FMEA的详情 Item Function/Requirement 项目的功能/要求4 Enter All Functio

49、ns of a Product Item4 键入所有产品的功能 Potential Failure Mode 潜在的故障模式4 Describe How a Product Item Could Fail4 描述产品怎样失效8Use Physical Terms,Not Symptoms8使用专用描述词语,不是症状Process FMEA过程过程FMEAGeneral Information-Details of the Product&FMEA 信息总说明-产品的详细资料和FMEA Process Function 过程功能4 Enter Description&Purpose of the

50、 Process4 键入过程描述和过程功能 Potential Failure Mode 潜在失效模式4 Describe How Process Could Fail to Meet Requirements of Subsequent Operations4 描述工艺为什么不能满足分序要求8Describe Non-conformance8描述不一致性35 2003 Eaton Corporation.All Rights Reserved.4/11/03FMEA Steps FMEA的步骤的步骤Design FMEA设计设计FMEAPotential Effect(s)of Failur