精益生產(chǎn)防錯

1、Error Proofing防錯Topics - Error Proofing TrainingTopics主題Objectives of the Training培訓(xùn)的目的What and Why of Error Proofing什么是防錯，怎樣進展防錯Application of Error Proofing防錯運用Identify Opportunities for Errors防錯時機確實定Overview of Failure Mode and Effects Analysis (FMEA)失效方式和效果分析總括Error Proofing Options防錯的選擇Preventi

2、on & Detection Through Poka Yoke Devices經(jīng)過Poka Yoke進展預(yù)防與探測Move to The Next Level轉(zhuǎn)入下一級A Benchmark Within Eaton伊頓內(nèi)部規(guī)范Summary概要Objectives of the Training培訓(xùn)的目的Understand What Is Error Proofing and What It Can Do了解什么是防錯和防錯能做什么Understand the Principles of Error Proofing了解防錯的原理Learn How to Apply Error Proo

3、fing to Products and Processes了解怎樣對產(chǎn)品及工藝過程運用防錯Learn About the Poka Yoke Devices and Systems了解Poka Yoke安裝和系統(tǒng)Learn the Process of Implementation and Continuous Improvements了解實施防錯的過程和繼續(xù)改良的過程What Are Your Expectations?他們的期望是什么？What and Why of Error Proofing什么是防錯以及為什么要防錯Definition定義Error Proofing Is a Sy

4、stematic Approach for Anticipating and Detecting Potential Defects and Preventing Them From Reaching the Customer(Internal or External)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)Error Proofing by Other Names以其他稱號進展防錯Fool Proofing防止愚笨行為Idiot Proofing防止白癡行為Mistake Proofing防止錯誤行為Fail Safing平安失效Poka YokeZe

5、ro Quality Control (Zero Defects)零質(zhì)量控制零缺陷Design for Manufacture and Assembly制造和裝配的設(shè)計Let Us Not Argue the Merits of These NamesLet Us Decide What We Want to Achieve我們不要爭論這些稱號,讓我們決議想要完成什么?Demoralizing Terms防錯術(shù)語Characteristics of Error Proofing防錯的特點Proactive Identification and Prevention前期識別及預(yù)防Prevent

6、First首先進展防錯Do Not Allow Defect From Going Further其次不準(zhǔn)許缺陷進一步開展Intentionally Designed, Not Happenstance設(shè)計錯誤,非偶爾錯誤.At the Source - Close to the Origination 錯誤的來源_接近發(fā)源地.Inexpensive First 首先本錢不高Transparent to the Operator 操作者很容易發(fā)現(xiàn)Absolutely Reliable 錯誤根源查找絕對準(zhǔn)確A Means to Achieve Zero Defect Product一種到達0缺陷

7、產(chǎn)品的方法Defects in Products Are the Imperfections (or Faults, or Flaws, or Blemishes, or Shortcomings, or Failings, or Deficiencies) 缺陷是指產(chǎn)品里的不完好性(或者缺點,或者裂紋,或者瑕疵，或者短處，或者過失，或者缺乏)Resulting From Errors錯誤產(chǎn)生的結(jié)果Errors Are Human Oversights (or Faults, or Blunders, or Boo-boos, or Slip-ups, or Inaccuracies or M

8、iscalculations) That Cause Defects in Products錯誤是人為忽略(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。Defects and Errors 缺陷和錯誤SO, Errors Cause Defective Products!所以,錯誤導(dǎo)致有缺陷的產(chǎn)品產(chǎn)生!Why Are Errors Made為什么會導(dǎo)致錯誤Any Product Is a Result of Numerous Decisions Made and Actions Taken by Human Beings, During:任何產(chǎn)品

9、都可以在下述一系列人為行為中產(chǎn)生錯誤：Product Design產(chǎn)品設(shè)計Process Design過程設(shè)計Equipment Design設(shè)備設(shè)計Component Fabrication Processes零件加工過程Product Assembly Processes產(chǎn)品裝配過程Inspection Processes檢驗過程Paperwork Generation程序行程過程Etc.等等And Human Beings are Fallible or Imperfect人是容易犯錯或不完美的SOME Examples of Defects屬于缺陷的一些例子Wrong or Inapp

10、ropriate Material錯誤或不適宜的資料Wrong or Non-functioning Components錯誤或者沒有功能的零件Wrong Dimensions or Tolerances尺寸或公過失誤Missing Components零件漏裝Foreign Matters, Contamination雜質(zhì)物質(zhì),污穢物Damaged Product or Components受損產(chǎn)品或零件Wrong Paperwork, or Wrong Product Shipped程序錯誤或者運輸了錯誤的產(chǎn)品Non-functioning or Malfunctioning Produc

11、t沒有功能的產(chǎn)品或者是缺點產(chǎn)品Wrong Shipping, or Wrong Billing運輸錯誤或者是填單錯誤SOME Examples of Causes of Defects導(dǎo)致缺陷的一些例子Poor Design Decisions設(shè)計比較乏味Omitted or Wrong Processing過程忽略或過程錯誤Missing / Extra Parts or Wrong Parts漏裝/多裝了錯誤的零件Omitted or Wrong Adjustment / Testing 脫漏調(diào)整/測試或調(diào)整/測試過程錯誤Wrong Equipment Setup or Loss of S

12、etup設(shè)備設(shè)置錯誤或沒有進展設(shè)備設(shè)置Wrong Material, Components or Assemblies資料，零件或者裝配錯誤Wrong Communication, Instructions, Procedures, or Methods錯誤的信息，指令，程序，或者方法Inexperience, Lack of Training, Wrong Training, Lack of Retraining缺乏閱歷，缺乏培訓(xùn)，培訓(xùn)錯誤，短少再培訓(xùn)SOME Examples of Results of Defects缺陷導(dǎo)致的結(jié)果例如Malfunction or Non-function

13、ing Product有缺點或者缺乏機能的產(chǎn)品Inconvenience, Discomfort, Injury, Death費事，不便，損傷，死亡Delays, Cancellations延期，取消Financial Losses財政損失Loss of Use or Productivity成效或者消費力的缺乏Damage to Customers Property損害客戶的利益Liabilities and Law Suites負(fù)債和法律問題Loss of Reputation and Business聲譽和業(yè)務(wù)受損SOME Causes of Human Errors導(dǎo)致人們犯錯誤的一些

14、緣由Forgetfulness, Loss of Concentration, Lack of Attention or Diverted Attention健忘，不集中，缺乏留意力或者轉(zhuǎn)移留意力Misunderstanding or Lack of Understanding誤解或者缺乏了解Lack of or Improper Experience / Training缺乏閱歷/培訓(xùn)或者不正確的閱歷/培訓(xùn)Lack of Standardization缺乏規(guī)范Intentional or Willful Error有意圖的或者惡意的錯誤Wrong or Delayed Decision決議錯

15、誤或拖延Limited or Lack of Sensory Capability (e.g., Smell, Color, Touch)有限的或者沒有感官才干例如，嗅覺，顏色，觸覺Lack of Application of Common Sense缺乏運用常識判別的才干Error Proofing in a Few Words預(yù)防錯誤的一些方法“ occurrence of defect was the result of some condition or action, and that it would be possible to eliminate defects entirel

16、y by pursuing the cause. The causes of defects lie in worker errors, and defects are the results of neglecting those errors. It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.缺陷的產(chǎn)生是一些環(huán)境或者行為導(dǎo)致的結(jié)果，但是完全有能夠經(jīng)過查找緣由排除缺陷。缺陷緣由在于工人，缺陷是由于工人忽視錯誤而產(chǎn)生的。假設(shè)

17、工人能及時的發(fā)現(xiàn)錯誤并且消除錯誤，就不會導(dǎo)致缺陷的產(chǎn)生。Shigeo ShingoWhy Error Proof?為什么防錯？99.9% Error Free Could Result in 99.9%沒有錯誤導(dǎo)致什么結(jié)果2,000,000 Documents Lost by IRS IRS短少2，000，000檔案16,000 Pieces of Mail Lost Every Day 每天喪失16，000郵件22,000 Wrongly Debited / Credited Checks Per Hour每個小時都會發(fā)生22，000寫錯借方和貸方的支票1,314 Wrongly Conne

18、cted Phone Calls Per Minute每個小時都會發(fā)生1，314起占線20,000 Incorrect Drug Prescriptions Per Year每個小時都會發(fā)生20，000起用錯藥物的情況12 Newborn Babies Given to Wrong Parents12個小孩被父母抱錯2 Unsafe Landings Every Day at OHare Airport每天都會有2起飛機不平安著陸32,000 Missed Heartbeats Per Person Each Year每年每個人都會有32，000Is 99.9% Good Enough? 99

19、.9% 夠不夠好?The Errors That Became Headlines錯誤變成頭條Titanic Sinking泰坦尼克號的沉沒Challenger Booster Rocket Seal Failure挑戰(zhàn)者號火箭發(fā)射失敗Mars Landing Module Crash火星升空失敗墜毀Hubbell Telescope Reflector ErrorHubbell望遠(yuǎn)鏡反射誤差Exxon Valdez Oil SpillExxon Valdez 石油泄露Chernobyl Nuclear Power Plant MeltdownChernobyl Nuclear Power 設(shè)

20、備報廢Release of Methyl Isocyanate (MIC) From Union Carbide Plant in Bhopal, India甲基異丙酮從Bhopal, India ,MIC碳化物廠房泄露Three Mile Island Nuclear Plant 三英里小島的核廠房Firestone Tires on Ford Explorer福特車上的耐火石探測器Error Proofing and Lean防錯及精益消費Lean Insists on One Piece Flow精益消費強調(diào)單件流If That One Piece Is Defective, Flow

21、Is Disrupte假設(shè)單件流有缺陷,流向就會被打斷Lean Insists on Limited Inventory精益消費強調(diào)有限庫存 If That Inventory Is Defective, the Lines Can Sto假設(shè)庫存有缺陷,線路就會停頓Lean Means Eliminating Waste精益是指消除浪費Defects and Corrective Actions Are Wast缺陷以及糾正措施是針對浪費Lean Requires That Equipment Is Ready When Needed and Functions Well As Long A

22、s Necessary精益消費要求當(dāng)需求設(shè)備時,設(shè)備馬上可以用,且功能完好Error Proofing the Tools, Fixtures, Setups, Methods and Documents Ensures Equipment Effectiveness 刀具,卡具,啟動,方法以及文件等防錯以確保設(shè)備的有效性Error Proofing Examples in Everyday Life在每天生活中防錯的一些例子Home家里Automatic Shutoff Irons全自動熨斗Ground Fault Circuit Breakers for Bathroom or Outdo

23、or Electric Circuits浴室或室外電氣線路的接地維護Pilotless Gas Ranges and Hot Water Heaters油量表以及熱水器Child-Proof Caps on Medicine Bottles藥瓶上維護小孩平安的瓶蓋Retail零售Tamper-Proof Packaging錐型防錯包裝Bar Coding at Checkou檢驗時的條碼Office辦公室Spell Check in Word Processing Software在 Word word處置軟件中進展拼寫檢查Verifying “Do you want to delete? W

24、hen Press the “Delete Buttonon Your Computer當(dāng)按刪除按鈕時電腦會訊問他“要刪除嗎?Factory工廠Dual Palm Buttons and Other Guards on Machinery 設(shè)備上運用兩個按扭及其他維護安裝Bar Coding條碼Lock-Out / Tag-Out 鎖緊/翻開標(biāo)簽Error Proofing Exercise No. 1防錯練習(xí)的第一部分Form Teams of Two兩個一組List As Many Examples of Error Proofing As You Can, From Everyday L

25、ife從他每天的生活中,列出他能作到的關(guān)于防錯的許多例子10 Minutes10分鐘Application of Error Proofing防錯的運用Essential Steps for Error Proofing防錯的根本步驟Identify Opportunities for Errors (Critical Factors)識別防錯的時機(關(guān)鍵要素)Prioritize Potential Errors for Error Proofing對潛在的錯誤加以，區(qū)分進展防錯Absolutely Must Prevent the Defects必需完全的防止錯誤Provide Conta

26、inment and Study Further預(yù)防錯誤和深化研討May Be Tolerated, Within Predefined Limits在方案的范圍內(nèi)進展防錯Identify Root Causes of the Errors識別錯誤根源Develop and Evaluate Error Proofing Options 開發(fā)和評價防錯方案Select and “Design the Error Proofing System選擇和設(shè)計防錯系統(tǒng)Implement - Plan, Install, Document, Train, Monitor實施防錯設(shè)計反錯，安裝防錯,編制防

27、錯文件,培訓(xùn),監(jiān)控Periodically Assess the Performance and Improve對防錯情況進展定期評審及改良Manufacturing Processes制造過程Product Quality產(chǎn)質(zhì)量量Process Design過程設(shè)計Product Design產(chǎn)品設(shè)計What is the Right Time to Error Proof?正確的防錯時間是什么時間?100:110:11:1As Early As Possible及早發(fā)現(xiàn)Why Error Proof Early During New Product Development為什么在新產(chǎn)品開發(fā)

28、期間防錯Cost of “Fixing the Defects “修繕缺陷的本錢Concept Development觀念開發(fā)Preliminary Design初步設(shè)計Detailed Product Design詳細(xì)的產(chǎn)品設(shè)計Customer Support客戶支持Industrialization產(chǎn)業(yè)化Production消費Process Design過程設(shè)計Cost of “Fixing 設(shè)備的破費Multiplies With Life Cycle Stages整個過程當(dāng)中的多項防錯Stages of Product Life Cycle產(chǎn)品生命周期中各個階段Why Error P

29、roof Early During Processing在處置期間為什么要盡早防錯Cost of “Fixing the Defects設(shè)備本錢失效Incoming Parts外協(xié)件After Completing the Process過程完成之后At the End of the Line產(chǎn)品最終分開消費線After Delivery to Customer 交付給客戶之后Final Test最后檢驗Cost of “Fixing Increases With Process Steps隨著程序步驟增長修復(fù)錯誤本錢增長Steps of Product Processing產(chǎn)品處置的步驟Re

30、ject & Return 廢棄件No Delay沒有拖延Reject & Scrap廢棄件&廢品Minor Delay略微拖延Reject & Scrap / Rework廢棄件&廢品/返工RescheduleSome Delay進度稍有拖延Significant Rework / ScrapAdd to the Production ScheduleDelayed Deliveries重要的返工/廢品影響消費進度及產(chǎn)品交付Warranty CostsAdministrative CostsLiabilitiesReputationMarket Share Loss擔(dān)保本錢及管理本錢添加,導(dǎo)

31、致市場份額損失Error Proofing Exercise No. 2防錯訓(xùn)練的第二部分Form Teams of Two兩個一組Discuss and Agree on One Example of Product Design or Manufacturing Process to Analyze討論一個產(chǎn)品設(shè)計或制造工藝的例子,并進展分析Identify 鑒別Error Proofing Implemented防錯實施Estimate Cost / Quality Impact消除本錢/質(zhì)量影響OR或者Error Proofing Opportunities Missed喪失防錯良機E

32、stimate the Cost / Quality Impact消除本錢/質(zhì)量影響List Lessons Learned學(xué)到的教訓(xùn)清單Prepare to Present to the Class預(yù)備到課堂上展現(xiàn)20 Minutes20分鐘Identify Opportunities for Errors識別防錯的時機Methods for Identifying Potential Errors識別潛在的防錯方法Customer Demanded - Good Start消費者的需求-良好的開場Internal Quality Results Reactive內(nèi)部質(zhì)量效果-反響Past

33、Experience - Not Completely Reliable以往閱歷-不完全可靠Customer 反響 - Too Late消費者的反響-太遲Systematic Analyses to Identify Potential Errors識別潛在的錯誤需進展系統(tǒng)分析Potential Failure Mode and Effects Analysis (FMEA)潛在的失效方式及效果分析(FMEA)Product FMEA 產(chǎn)品FMEAProcess FMEA過程FMEAPotential Failure Mode and Effects AnalysesPFMEA潛在的失效方式和

34、 效果分析Overview總攬Key Points of FMEAFMEA的關(guān)鍵部分FMEA Analyses Potential FailuresFMEA分析潛在失效Fleas Have to Be Done by Multi-functional TeamsFleas應(yīng)由多功能組執(zhí)行Design FMEA Should Be Initiated Before or at the Concept Stage設(shè)計FMEA是在開場之前或者概念構(gòu)成階段Process FMEA Should Be Initiated Before or at the Feasibility Stage, Prior

35、 to Tooling or Equipment Finalization過程FMEA是在工裝及設(shè)備調(diào)整好開場消費之前或者可研階段FMEAs Should Be Continuously Updated, As Changes in Product & Process Designs Take Place 應(yīng)該不斷更新,比如FMEAs中的產(chǎn)品&過程設(shè)計 FMEAs Are Living Documents FMEAs 是活的文件FMEAs Are Never Ending Processes FMEAs 是永遠(yuǎn)都不會終了的工藝FMEA Type and LevelsFMEA的類型和程度Desi

36、gn FMEA設(shè)計FMEAProcess FMEA過程FMEASubsystem子系統(tǒng)Critical Features關(guān)鍵特性Components / Parts零件Subassemblies分裝Workstations任務(wù)臺Operations加工操作General Information (1)總闡明23456781011912FMEA Steps FMEA 的步驟Design FMEA設(shè)計FMEAGeneral Information - Details of the Product & FMEA信息總闡明-產(chǎn)品及FMEA的概略Item Function / Requirement工程

37、的功能/要求Enter All Functions of a Product Item鍵入一切產(chǎn)品的功能Potential Failure Mode潛在的缺點方式Describe How a Product Item Could Fail描畫產(chǎn)品怎樣失效Use Physical Terms, Not Symptoms運用公用描畫詞語,不是病癥Process FMEA過程FMEAGeneral Information - Details of the Product & FMEA信息總闡明- -產(chǎn)品的詳細(xì)資料和FMEAProcess Function 過程功能Enter Description

38、& Purpose of the Process鍵入過程描畫和過程功能Potential Failure Mode 潛在失效方式Describe How Process Could Fail to Meet Requirements of Subsequent Operations描畫工藝為什么不能滿足分序要求Describe Non-conformance描畫不一致性FMEA Steps FMEA的步驟Design FMEA設(shè)計FMEAPotential Effect(s) of Failure潛在失效效果Perceived by Customer客戶需求Severity (Chart)嚴(yán)肅

39、性圖表Seriousness of the Effect of Potential Failure潛在失效效果的嚴(yán)肅性Severity Ranking Reduced Only by Design Change只需設(shè)計更改時嚴(yán)肅性級別降低Classification分類Safety / Regulation or Function / Appearance Based平安/規(guī)定或功能/根本表象Employ Customers Criteria采用客戶規(guī)范Process FMEA過程FMEAPotential Effect(s) of Failure潛在失效效果Perceived by Cust

40、omer, Including Subsequent Operations客戶需求,包括下述操作Severity (Chart) 嚴(yán)肅性(圖表)Seriousness of the Effect of Potential Failure潛在失效效果的嚴(yán)肅性Classification分類Safety / Regulation or Function / Appearance Based平安/規(guī)定或功能/根本表象Employ Customers Criteria采用客戶規(guī)范Severity Rating Chart嚴(yán)肅性級別表格FMEA Steps FMEA步驟Design FMEA 設(shè)計FME

41、APotential Cause(s)潛在緣由List All the Causes (Design Weaknesses)列出一切緣由(設(shè)計弱點)Occurrence (Chart)頻率(圖表)Likelihood of the Failure to Occur by the Specific Cause特殊緣由導(dǎo)致失效的能夠性O(shè)ccurrence Ranking Reduced Only by Design Change僅當(dāng)設(shè)計更改時才思索降低發(fā)生頻率.Design Control設(shè)計控制Validation / Verification Activities Which Will Ass

42、ure Adequacy of Design驗證/確認(rèn)活動應(yīng)確保設(shè)計的準(zhǔn)確性Process FMEA 過程FMEAPotential Cause(s)潛在緣由Identify Root Cause, and Identify What Can Be Corrected確定緣由,確定可以采取什么糾正措施Occurrence (Chart)頻率(圖表)Expected Frequency of Failure to Occur by Specific Cause 詳細(xì)緣由導(dǎo)致失效發(fā)生的頻率Classification (Chart)類別Process Controls That Prevent o

43、r Detect the Failure預(yù)防或探測缺陷的過程控制Occurrence Rating Chart 頻率等級表格FMEA Steps FMEA 的步驟Design FMEA設(shè)計FMEA Detection (Chart) 檢測圖表Ability of a Current Design Control to Identify a Potential Cause現(xiàn)行控制設(shè)計才干,以識別潛在的緣由當(dāng)前設(shè)計的才干Process FMEA過程FMEA Detection (Chart) 檢測圖表Assuming Failure Has Occurred, Assess Detection C

44、apability of All the Process Controls假設(shè)發(fā)生失效,應(yīng)檢測一切工藝控制的才干RPN (Risk Priority No.) RPN(風(fēng)險優(yōu)先號)Product of S (Severity), O (Occurrence) & D (Detection)產(chǎn)品的S(嚴(yán)重性),O(發(fā)生頻率)&D(檢測)Used As a Guide to Help Rank Design / Process Concerns為進展設(shè)計及過程等級等提供導(dǎo)游No Threshold Value無界限值Pay Special Attention If Severity Is High

45、假設(shè)嚴(yán)重級別高的話,應(yīng)提高警惕Corrective Action, Responsibility, and Monitoring Results實施糾正措施,確定責(zé)任人,監(jiān)控結(jié)果1112Detection Rating Chart檢測等級表Summarized Rating Chart總結(jié)等級表Summary of FMEA Steps FMEA步驟匯總Form a Multi-functional Team組建多功能小組Failure Mode: How Could This Part, System or Process Fail?失效方式:該產(chǎn)品,系統(tǒng)或工藝是怎樣失效的?Effect o

46、f the Failure: What Does the Customer Experience As a Result of the Failure?失效影響:作為一種失效方式客戶的閱歷是怎樣的?Cause of Failure: What Conditions Could Bring About the Failure Mode?失效緣由:關(guān)于該失效方式會導(dǎo)致什么情況?Occurrence: Probability the Failure Mode Will Occur發(fā)生:發(fā)生失效方式的能夠性Severity: Weighing the Consequence of the Failur

47、e Mode嚴(yán)重性:衡量失效方式的結(jié)果Detection: Probability the Failure Mode Will Not Be Detected Before Reaching the Customer 失效:失效方式在到達客戶之前不會被檢測到.Risk Priority No. (RPN): Product of Occurrence, Severity and Detection, That Provides Relative Priority.風(fēng)險號(RPN): 產(chǎn)品發(fā)生頻率,嚴(yán)重性檢測,提供了相對優(yōu)先權(quán).Identify Action Items, Assign Resp

48、onsibility, and Follow Through確定實施措施:分配責(zé)任,跟蹤執(zhí)行Essential Steps for Error Proofing 防錯的根本步驟Identify Opportunities for Errors (Critical Factors)Prioritize Potential Errors for ProofingAbsolutely Must Prevent the DefectsProvide Containment and Study FurtherMay Be Tolerated, Within Predefined LimitsIdenti

49、fy Root Causes of the ErrorsDevelop and Evaluate Error Proofing Options Select and “Design the Error Proofing SystemImplement - Plan, Install, Document, Train, MonitorPeriodically Assess the Performance and ImproveFMEA Addresses All these Error Proofing Steps FMEA可以定位一切的防錯步驟And Helps Planfor These為此

50、設(shè)置方案Exercise - 3 Process PFMEA 過程PFMEA練習(xí)第三部分Identify One of the Process Steps識別一個過程步驟Walk Through the Steps of PFMEA實施整個PFMEA步驟Fill Out the FMEA Form填寫FMEA表格Develop an Action Plan開發(fā)實施方案Error Proofing Options防錯方案Error Proofing Approaches防錯方法Eliminate Potential Defects: Design Out the Potentials for E

51、rrors消除潛在缺陷:對潛在錯誤進展設(shè)計Prevent Defects From Occurring: Identify the Potential of Error, Before It Occurs, and Prevent It防止缺陷發(fā)生:識別潛在錯誤:在錯誤發(fā)生前進展預(yù)防Detect the Defect: Error Has Already Occurred, Detect and Remove the Defective Product 檢測缺陷:錯誤曾經(jīng)發(fā)生,檢測及移除缺陷件Loss Control: Potential for Defect Exists, Potentia

52、l Exists for Not Detecting, Minimize Damage From the Defect損失控制:存在潛在缺陷,沒有對潛在缺陷進展探測,使缺陷的損傷最小化.All These Approaches Overlap, No Clear Boundaries一切方法交錯在一同,沒有明晰界限Example - Fire Proofing a New Building例如-新 建筑的防火防錯Eliminate: Use Only Non-combustible Material for Construction (Steel, Concrete, Etc.)排除：在建筑中

53、要運用不易燃物質(zhì)鋼鐵，混凝土等Prevent: Do Not Allow不允許吸煙Electrical System and Components運用正確的電氣系統(tǒng)和元件預(yù)防：Detect: Install Smoke Detectors and Fire Alarms檢測：安裝煙霧檢測器和火警系統(tǒng)Loss Control: Install Sprinkler System, Fire Extinguishers, Fire Hoses損失控制：安裝自動噴淋安裝系統(tǒng)，滅火器，滅火水龍帶，防火軟管等Example - Accident Proof a Railway Crossing例子：測試鐵

54、道路口的不測事故Eliminate Accidents: Build a Bridge排除事故：建造一座橋Prevent Accidents: Install an Automatic Gate, In Addition to Lights and Alarms預(yù)防不測事故：除了燈和警報安裝,安裝一個自動門Detect and announce a Passing Train: Install Lights and Alarms檢測和進展一個短期培訓(xùn)：安裝燈和警報安裝培訓(xùn)Loss Control, in Case of an Accident: Install a Pay Phone?損失控制

55、，有不測事故時：安裝一個付費?In Many Cases, Loss Control Is NOT an Option在很多情況下,損失控制不是實施方案First Step for Error Proofing Options防錯的第一個步驟Decide the Level of Error Proofing Needed需求決議防錯的程度Eliminate, If排除，假設(shè)Severity Is High嚴(yán)重度高Potential for Occurrence Is Very High發(fā)生的能夠性很大Detection Is Impossible檢測是不能夠的Cost of Eliminat

56、ing is Low排除本錢低Prevent, If Design Is Completed, and防止，假設(shè)設(shè)計完成Severity Is Low嚴(yán)肅性較低RPN Is Low RPM低Attempt Detection in Most Other Cases of Potential for Defects對其他潛在缺陷進展檢測Based on Priority以優(yōu)先權(quán)為根底Opportunities for Error Proofing防錯的良機消除預(yù)防檢測損失控制產(chǎn)品設(shè)計 工藝/設(shè)備設(shè)計 車間措施 其他質(zhì)量保證措施Error Proofing Decision Diagram防錯決策

57、圖表Potential Error潛在的錯誤Defect Free Product無缺陷產(chǎn)品Errors Eliminated排除錯誤Prevent Error from Occurring防止錯誤發(fā)生Eliminate During Product / Process Design在產(chǎn)品/過程設(shè)計中消除錯誤Detect the Defect發(fā)現(xiàn)缺陷Defect Detected缺陷檢測Defect Prevented缺陷防止Design Loss Control In the Product在產(chǎn)品中設(shè)計損失控制Defect Has Serious Consequences缺陷導(dǎo)致嚴(yán)重結(jié)果No

58、NoNoNo無Yes有YesYes有YesDevelop Loss Control Procedure開發(fā)損失控制程序Key Points for Elimination錯誤排除的關(guān)鍵點Largest Potential During Design設(shè)計中的宏大潛能Eliminate by Designing Out Activities With Potential for Errors對潛在的錯誤設(shè)計活動,進展排除Cost Effective If Addressed Before Finalizing the Designs (Product, Process, Equipment)設(shè)計定

59、案之前產(chǎn)品，程序，器材計算本錢成效Most Cost Effective Method of All大多數(shù)本錢成效方法Six Sigma Quality Can Be Achieved Only With Extensive Elimination 只需完成大范圍消除措施后才可以完成6 SigmaMotorola Mandates All Processes for a New Product to Be Six Sigma Capable摩托羅拉要求一切產(chǎn)品工藝都可以運用6Sigma.Once Eliminated, Nothing Else is Required一旦消除,就不需求其他的了

60、Error Elimination & Symmetry排除錯誤和對稱L1L2L1L1Make Them Asymmetric 使其不均勻分布Make Them Completely Symmetric使其完全均勻分布Partially Symmetric Parts部分平衡件OR或Error Elimination & Dimensioning排除防錯和決議錯誤大小Which is Better?哪一個最好？Ask What is Important and How It Should be Measured什么是重要，應(yīng)怎樣丈量To EliminateModify or Redesign?