防誤措施學(xué)習(xí)課件

MISTAKE-PROOFING

防誤措施第一頁(yè)，共二十七頁(yè)。

ACEElementsQCPCRootCause/CorrectiveActionPassportProcessManagementStandardWorkMistakeProofingMarketFeedbackAnalysis6SQualityClinicActivityTPM第二頁(yè)，共二十七頁(yè)。

ACE內(nèi)容質(zhì)量診斷程序圖表根本原因修正行動(dòng)設(shè)計(jì)開(kāi)發(fā)通行證程序管理標(biāo)榜化作業(yè)防誤措施市場(chǎng)反饋分析6S質(zhì)量診斷行動(dòng)全面生產(chǎn)性維護(hù)第三頁(yè)，共二十七頁(yè)。ACEElementsEngineeringNewProducts,Processes&SystemsPassport-Systematicmethodforreview/approvalofnewdesigns

StandardMethod

ProcessManagement-Meanstoidentify&mapkeybusinessprocessesStandardWork-Repeatableprocessesthatareeffectiveandefficient

QualityImprovementMethodsQCPC-Simpletooltoidentifyproblemsandinefficiencies(turnbacks)

MFA-DatasummariesthatdisplayhowcomponentsperforminfieldRootCause-Methodtodrivetothetruesourceofproblems

StandardEnvironmentNew6S-WorkplaceorganizationandvisualcontrolTotalProductiveMaintenance-Continuouslyimprovingequipment effectiveness/availability Mistake-Proof-Creationofdevicesthatensureataskisalways donecorrectly第四頁(yè)，共二十七頁(yè)。ACE內(nèi)容開(kāi)發(fā)新產(chǎn)品、程序和系統(tǒng)設(shè)計(jì)開(kāi)發(fā)通行證

-檢查/批準(zhǔn)新設(shè)計(jì)的系統(tǒng)方法標(biāo)準(zhǔn)方法

程序管理–識(shí)別并展示重要商業(yè)程序的方法

標(biāo)準(zhǔn)化作業(yè)-可重復(fù)的有效程序

質(zhì)量改進(jìn)方法

質(zhì)量診斷程序圖表-識(shí)別問(wèn)題和低效率（返工）的簡(jiǎn)單工具

市場(chǎng)反饋分析-展示組件是怎樣工作的數(shù)據(jù)摘要

根本原因-發(fā)現(xiàn)問(wèn)題的真正來(lái)源的方法

標(biāo)準(zhǔn)環(huán)境

新6S-工作場(chǎng)地組織和直觀(guān)控制

全面生產(chǎn)性維護(hù)-不斷地改善設(shè)備的有效性和可用性

防誤措施-確保任務(wù)總能正確完成的設(shè)備的措施第五頁(yè)，共二十七頁(yè)。Increaseprofitabilitybyeliminatinginadvertentmistakes消除無(wú)謂的錯(cuò)誤可增加利潤(rùn)率Increaseproductivitybyreducingwastedtime減少浪費(fèi)的時(shí)間可提高生產(chǎn)力Improvecustomersatisfactionandqualitybyeliminatingescapes消除逃脫可提高客戶(hù)滿(mǎn)意度和質(zhì)量Increasereliabilitybycontinuouslyimprovingproducts,servicesorprocesses不斷改進(jìn)產(chǎn)品、服務(wù)或程序可提高信譽(yù)BenefitsofMistake-Proofing

防誤措施的好處第六頁(yè)，共二十七頁(yè)。Theyarenotthesamething!MistakesCauseDefects.他們是不同的！錯(cuò)誤導(dǎo)致過(guò)失Mistakesvs.Defects錯(cuò)誤vs過(guò)失Mistake錯(cuò)誤Defect過(guò)失Pumpingdieselfuelintoyourgastank.將柴油加入汽油箱Runningaredlight.撞紅燈Forgettingtounplugyouriron.忘記拔掉電熨斗的插頭Placingthe“original”inyourcopierfeeder“facedown”.將原件放進(jìn)了復(fù)印機(jī)的進(jìn)紙?zhí)幉⒄鏇_下or第七頁(yè)，共二十七頁(yè)。Misunderstandingrequirements誤解了要求Skippingaprocesssteportasks漏掉了一個(gè)工作步驟Performingprocessstepsincorrectlyorinthewrongorder未正確地或以錯(cuò)誤地順序執(zhí)行程序步驟Contamination污染MostCommonMistakes

最常見(jiàn)的錯(cuò)誤Leavingoutapartorapieceofinformation漏掉了一個(gè)零件或一條信息Adjustmentandmeasurementmistakes調(diào)節(jié)和測(cè)量錯(cuò)誤Timingmistakes定時(shí)錯(cuò)誤Usingthewrongpart,toolorinformation使用了錯(cuò)誤的零件、工具或信息第八頁(yè)，共二十七頁(yè)。Mistake-Proofingisawayofusingwisdomandingenuitytocreatedevicesthatensureataskisalways

donecorrectly.防誤措施是指運(yùn)用智慧和獨(dú)創(chuàng)性發(fā)展出一個(gè)能確保任務(wù)總是能正確完成的設(shè)備的方法。Mistake-Proofing

防誤措施Itremovesuncertaintyfromthesituationswhereerrorsaremostlikelytooccur,suchas:它去除了最可能發(fā)生錯(cuò)誤的情形中的不確定性，如：

Repetitivetasks重復(fù)性的任務(wù)Complexinstructions復(fù)雜的說(shuō)明書(shū)Calculations/Adjustments計(jì)算/調(diào)節(jié)Look-alikeparts相似的零件第九頁(yè)，共二十七頁(yè)。WhydowedoMistakeProofing?

為什么我們要采用防誤措施？Topreventturnbacksandcustomerescapes

fromrecurring,sincethecosttofixaproblemincreasesrapidlythelateritisfound:為防止缺陷和客戶(hù)逃脫情況再次發(fā)生，因?yàn)閱?wèn)題發(fā)現(xiàn)得越晚所花的費(fèi)用就會(huì)迅速增加：Ifadefectoccurshere如果在這兒發(fā)生過(guò)失andit’sfoundhere,并在這兒被發(fā)現(xiàn)，

itcosts:

就要花費(fèi)：Rework,repair,scrapandescapescostUTC$148millionperyear.Warrantyexpensescostusanother$600millionperyear.Thecostoflostcustomerloyaltyduetoescapesisimmeasurable.返工、修理、廢棄和逃脫每年要花掉UTC1.48億。保修費(fèi)用每年花掉我們另外6億。由于逃脫而喪失了客戶(hù)的信任的損失則不可計(jì)算。Design設(shè)計(jì)Develop

Process進(jìn)行加工Op2Customer客戶(hù)Op1Op1Op2$1$10$100$1,000$10,000第十頁(yè)，共二十七頁(yè)。Mistake-Proof防誤措施theDesign設(shè)計(jì)Redesigntheproduct重新設(shè)計(jì)產(chǎn)品

Eliminatethemistakecondition消除犯錯(cuò)誤的條件Redesignforsymmetryorasymmetry重新進(jìn)行對(duì)稱(chēng)或不對(duì)稱(chēng)設(shè)計(jì)Changethematerials改變材料Changecomponenttype,characteristicsorsupplier改變組件的類(lèi)型、特征或供應(yīng)商2ApproachestoMistakeProofing

預(yù)防錯(cuò)誤的2個(gè)途徑Mistake-Proof

防誤措施theProcess加工Changeoraddtooling改變或增添工具Changeprocesssteps改變加工步驟Adduseofchecklists,templatesorgages增加使用清單、模板或測(cè)量?jī)xImplementcontrolcharts執(zhí)行控制圖表第十一頁(yè)，共二十七頁(yè)。ProcessDescription:Makingapotofcoffee程序描述：泡一壺咖啡ExampleofMistake-ProofingtheDesign

防誤措施范例設(shè)計(jì)BeforeImprovement:改進(jìn)前： Waterneededtobemeasuredforeachpotofcoffeeoftenresultingincoffeethatwastooweakortoostrong

泡前每壺咖啡的水量都要測(cè)量常常導(dǎo)致咖啡過(guò)淡或過(guò)濃。第十二頁(yè)，共二十七頁(yè)。ProcessDescription:Makingapotofcoffee程序描述：泡一壺咖啡ExampleofMistake-ProofingtheDesign

防誤措施范例設(shè)計(jì)AfterImprovement:改進(jìn)后： Coffeemakerwasredesignedtomeasureandaddthepreciseamountofwaterfromawaterbottle 重新設(shè)計(jì)咖啡機(jī)以使每次從水瓶中加入的水的量都一樣多第十三頁(yè)，共二十七頁(yè)。ProcessDescription:Alabelispastedintoarecessinamoldedchassis程序描述：將標(biāo)簽貼在底盤(pán)的凹槽內(nèi)ExampleofMistake-ProofingtheDesign

防誤措施范例設(shè)計(jì)BeforeImprovement:改進(jìn)前：Therecessandthelabelwerebothrectangular.Thelabelcouldbegluedinupside-down.凹槽和標(biāo)簽都是長(zhǎng)方形。標(biāo)簽可能會(huì)貼反。Recessin

chassis底盤(pán)的凹槽Label標(biāo)簽ModelT6AC110V10WAfterImprovement:改進(jìn)后：Anotchwasmadeinthecornerofthelabel,andintherecessofthechassis.Incorrectmountingiscompletelyeliminated.在標(biāo)簽和凹槽的一角做一個(gè)切口。就能完全防止錯(cuò)誤發(fā)生。Recessin

chassis底盤(pán)的凹槽Label標(biāo)簽ModelT6AC110V10W第十四頁(yè)，共二十七頁(yè)。ExampleofMistake-ProofingtheDesign

防誤措施范例設(shè)計(jì)ProcessDescription:Installslidesintoaslideprojector程序描述：將幻燈片裝入幻燈機(jī)中BeforeImprovement:改進(jìn)前：Aresomeslidesupsidedown?有一些幻燈片裝反了嗎？AfterImprovement:改進(jìn)后：Topedgeofeachslidemarkedwithareddot.每張幻燈片的上邊都有一紅點(diǎn)。第十五頁(yè)，共二十七頁(yè)。ExampleofMistake-ProofingtheDesign

防誤措施范例設(shè)計(jì)ProcessDescription:Torquinganumberofboltsrecesseddeepinacavity.程序描述：將大量螺栓擰進(jìn)空腔深處的凹槽內(nèi)BeforeImprovement:改進(jìn)前：Thesocketextensionrequiredtoreachtheboltscausednicksandscratchesinthepaintedsurfacesthatitcontactedduringassembly.在操作的過(guò)程中，用來(lái)擰螺栓的擰桿柄會(huì)對(duì)油漆表面造成刮傷。AfterImprovement:改進(jìn)后：Arubberhosewasinstalledoverthesocketextensionandwasspecifiedontheworkinstructions.一個(gè)橡皮管被裝在擰桿柄上并在工作說(shuō)明書(shū)上有詳細(xì)說(shuō)明。第十六頁(yè)，共二十七頁(yè)。Mistake-Proofingisawayofusingwisdomandingenuity

tocreatedevicesthatensureataskisalwaysdonecorrectly.防誤措施是指運(yùn)用智慧和獨(dú)創(chuàng)性發(fā)展出一個(gè)能確保任務(wù)總是能正確完成的設(shè)備的方法。Mistake-Proofingisn’tWords!

防誤措施不是文字！Word“Solution”文字“解決方法”P(pán)roblem:The“OneDay“employeebadgeformasksforbadge#andclock#.Employeesoftenwritetheirclock#inthebadge#spot.問(wèn)題：“一日”雇員的證件表格要求填寫(xiě)證件號(hào)和鐘點(diǎn)號(hào)。雇員常將鐘點(diǎn)號(hào)填在證件號(hào)的位置。Badge#證件號(hào)Clock#鐘點(diǎn)號(hào)(filledoutbyEmergencyServices)（由緊急服務(wù)部填寫(xiě)）(filledoutbyemployee)（由雇員填寫(xiě)）TrueMistake-Proofing真正的防誤措施1DayBadge#1日證件號(hào)AllgrayareasfilledoutbyEmergencyServices所有灰色區(qū)域由緊急服務(wù)部填寫(xiě)EmployeeClock#雇員鐘點(diǎn)號(hào)AllyellowareasfilledoutbyEmployee所有黃色區(qū)域由雇員填寫(xiě)第十七頁(yè)，共二十七頁(yè)。Guidepinsorinterferencepins向?qū)D釘或干涉圖釘Templates模板Partkitsusingshadowboxing使用能防止錯(cuò)誤的零件包Limitswitches限制閥MostCommonTypesofMistake-ProofDevices

最常見(jiàn)的防誤設(shè)備Counters計(jì)算器Alarms鬧鐘Weightsandmeasures稱(chēng)重秤和測(cè)量?jī)xChecklists清單Controlcharts控制圖表第十八頁(yè)，共二十七頁(yè)。Mistake-ProofingProcessChanges

防誤碼程序的改變Improvetheprocess!改進(jìn)程序！Simplify簡(jiǎn)單化Reducesteps,parts,forms,dataonforms,numberofprocesssteps,etc.減少步驟、零件、表格、表格上的數(shù)據(jù)、加工步驟的數(shù)量等。Consolidate/Co-Locate鞏固/共用Bringoperationsclosertogether,reducework-in-process(WIP)使操作變得更緊湊，減少過(guò)程工作（WIP）Standardize標(biāo)準(zhǔn)化Maketheprocessvisual使程序可見(jiàn)Moveresponsibilityandauthoritydownintheorganization將責(zé)任和權(quán)利下放給組織第十九頁(yè)，共二十七頁(yè)。Try-Storming(vs.Brainstorming)嘗試風(fēng)暴（對(duì)頭腦風(fēng)暴）Involvetherightpeople讓合適的人參與Walktheprocessandgetthefacts檢驗(yàn)程序并獲得事實(shí)Don’tjustsitandthinkaboutsolutions...TRYTHEM!不要只是坐在那兒想解決問(wèn)題的方法…去嘗試！CreatingMistakeProofing

創(chuàng)建防誤措施第二十頁(yè)，共二十七頁(yè)。The“NastyTest”(vs.the“Solution”)“惡心的試驗(yàn)”（對(duì)“解決方法”）Whenyouthinkyou’vegotthebestsolution…TRYTOMAKEITFAIL!!!當(dāng)你認(rèn)為你已找到最佳解決方法時(shí)… 試著去讓它失敗Involveallusers讓所有使用者參與Mistake-proofdevicesmustbe100%effectiveatdealingwithaparticularmistake在處理特殊錯(cuò)誤時(shí)防誤設(shè)備必須100%有效Ifnot,theywillbeignored如果不能，就應(yīng)放棄Ensurethemistake-proofdoesn’tcreateanotherproblem確保防誤措施不會(huì)引起其它問(wèn)題TestMistakeProofingwiththe“NastyTest”

用“惡心的試驗(yàn)”來(lái)驗(yàn)證防誤措施第二十一頁(yè)，共二十七頁(yè)。Formally,aspartoftheQCPC/MFAProcess 形式上的，作為QCPC/MFA程序中一部分WhendoyoudoMistake-Proofing

何時(shí)采取防誤措施Noticemistakeasithappens當(dāng)錯(cuò)誤發(fā)生時(shí)要留意Developasimplefixtopreventitfromrecurring.開(kāi)發(fā)出一種簡(jiǎn)單方法來(lái)防止它再發(fā)生Implementthesimplefixintothestandardprocess在標(biāo)準(zhǔn)程序中運(yùn)用這種簡(jiǎn)單方法UseQCPCtocollectTurnbackdata使用QCPC來(lái)收集缺陷數(shù)據(jù)UseParetoAnalysistoIdentifytopturnbacks用Pareto分析來(lái)識(shí)別最高缺陷率PerformRootCauseAnalysistoidentifyRootCause用根本原因分析來(lái)識(shí)別根本原因Develop&implementMistake-Proofs

topreventrecurrence.開(kāi)發(fā)并執(zhí)行防誤措施來(lái)防止錯(cuò)誤的再發(fā)生2)Real-time,wheneveryounoticeamistaeoccurringorthepotentialforamistake實(shí)時(shí)的，無(wú)論何時(shí)你發(fā)現(xiàn)一個(gè)錯(cuò)誤或有出錯(cuò)的可能性第二十二頁(yè)，共二十七頁(yè)。Thereare3LevelsofMistake-Proofingbasedoneffectivenessandspeed:防誤措施有三個(gè)基于有效性和速度的等級(jí)： LevelIII:Detection

等級(jí)三：發(fā)現(xiàn) LevelII:Alert

等級(jí)二：警告LevelI:Prevention等級(jí)一：防止ThreeLevelsofMistake-Proofing

防誤措施的三個(gè)等級(jí)第二十三頁(yè)，共二十七頁(yè)。LevelIII,Detect:AllowsyoutodetectyourMistakeafterithasoccurred.(1point)等級(jí)三，發(fā)現(xiàn)：在已經(jīng)發(fā)生之后發(fā)現(xiàn)錯(cuò)誤Checklists清單Computerbeeps電腦提醒

ManuallyactivatedSpellCheck手工拼寫(xiě)檢查L(zhǎng)evelII,Alert:AlertsyouastheMistakeishappening.(2points)等級(jí)二，警告：當(dāng)錯(cuò)誤正在發(fā)生時(shí)提醒你Sensors,alarms,controlcharts

傳感器、鬧鐘、控制圖表Counters計(jì)算器AutomaticSpellCheck自動(dòng)拼寫(xiě)檢查L(zhǎng)evelI,Prevent:PreventsyoufrommakingtheMistake.(3points)等級(jí)三，防止：防止你犯錯(cuò)誤Eliminatingthemistakecondition(changingthedesign)消除犯錯(cuò)條件Automation自動(dòng)控制Spelling“Auto-corrector”拼寫(xiě)“自動(dòng)更正器”ThreeLevelsofMistake-Proofing

防誤措施的三個(gè)等級(jí)第二十四頁(yè)，共二十七頁(yè)。MistakeProofingQualifyingLevelItems

防誤措施合格水平內(nèi)容Thefollowing2itemsarerequiredtoachievetheACEQualifyinglevelforMistakeProofing要取得ACE的防誤措