奥特利夫精益生产之-防错ErrorProofing

PRIVATE/PROPRIETARY1APSTrainingModuleQF–ErrorProofingAutoliv14-April-2006QF-TM-018-C1.0PRIVATE/PROPRIETARY2QualityassuranceQualitymethodsSixSigmaStandardsPullsystemSafety&ErgonomyDon’tjudge,don’tblame!Flexibility&MotivationDisciplinetostandardsContinuousimprovementProcess&ResultQualityfirstProfitabilityCompetitivenessSatisfactionEmployeeinvolvementTeamwork5SMudaeliminationTPMJustintimeLeveling&CapacityLineconceptsContinuousflowTakttimeFrequentdeliveriesQualityassurancePRIVATE/PROPRIETARY3WhythistrainingDuringthistrainingyouwilllearn:•MeaningofErrorProofing•Differencebetweendefectanderror•ThegoalofErrorProofing•DifferenttypesofErrorProofingPRIVATE/PROPRIETARY4WhatisToday’sTopic?PRIVATE/PROPRIETARY5DEFINITIONPOKA=ERRORSYOKE=AVOIDTRANSLATIONFROMJAPANESEErrorProofingisalsoknownasPokaYokePRIVATE/PROPRIETARY6ErrorProofingThethreetypesoferrorproofingare:AnticipatingPreventingDetectingWhatisthedifferencebetweenanerrorandadefect?ERRORSANDDEFECTSPRIVATE/PROPRIETARY7ErrorsLeadtoDefectsDefectsError(s)Man/PeopleMachineMethod/ProcessMaterialsMeasurementMotherNatureManagementCauseCausePRIVATE/PROPRIETARY8EffectivenessofManualChecks/InspectionsYouworkforthe“r”countingservices.•Countallther’sinthenextslide•Youhave60secondsPRIVATE/PROPRIETARY9Errorsareoftenidentifiedwithmistakes.Arenoterrorsandmistakesreallythesamething?Ourperspectiveonthematteraffirmsourposition.Whatisrealandcorrecttoonemaynotbetotheother.Letusbecarefulandrecognizeourparadigms.Istherereallyarightorwronganswertothequestion?Theperspectiveofratherdetailedthinkersmaycreatefinedistinctions.Ofcourse,theremaybesomevalueindifferentiatingbetweenthevariousdefinitionsoferrorandmistakeproofingasdiscoveringunderlyingprinciplesoferrorproofingareexposedthroughcarefulandrigorousexamination.PRIVATE/PROPRIETARY10E��o�sa�eoftenidentifiedwithmistakes.A�enote��o�sandmistakes�eallythesamething?Ou�pe�spectiveonthematte�affi�msou�position.Whatis�ealandco��ecttoonemaynotbetotheothe�.Letusbeca�efuland�ecognizeou�pa�adigms.Isthe�e�eallya�ighto�w�onganswe�tothequestion?Thepe�spectiveof�athe�detailedthinke�smayc�eatefinedistinctions.Ofcou�se,the�emaybesomevalueindiffe�entiatingbetweentheva�iousdefinitionsofe��o�andmistakep�oofingasdiscove�ingunde�lyingp�inciplesofe��o�p�oofinga�eexposedth�oughca�efuland�igo�ousexamination.Therewere53r’s.PRIVATE/PROPRIETARY11Howdidyoudo?Howmanyr’sdidyoufind?Whatcouldhavebeendonetomakefindingther’smoreeffective?Howcanweapplythistousinginspectionmethodsforerrorproofing?PRIVATE/PROPRIETARY12ErrorProofingPrinciples&PhilosophyPRIVATE/PROPRIETARY13ErrorProofingBasicPrinciples•Equipmentandtoolswearoutand/orbreak•Thingschange•PeoplemakemistakesPRIVATE/PROPRIETARY14PeopleMakeMistakesOurhumancapacitiesarelimited•Wecanonlystore4-7thingsinourshorttermmemory•Minimizethenumberofthingstorememberatonce•Group/categorize/chunkinformationandsteps•Wegetdistracted•Havecheckstoensurestepsarecorrectandcomplete•Wehavelimitations(colorblindness,dyslexia,etc.)PRIVATE/PROPRIETARY15ErrorProofingPhilosophyMakeiteasytoproducegoodquality•PreventinadvertentmistakesPeoplewanttobuildgoodparts•Peoplecanbeatanysystemiftheyreallywantto•Focusonwhatcreatedtheerror,notwho•“Howcanwepreventthisfromhappeningagain?”Or“Howcanwemakeiteasiertonoticeorpreventabnormalities?”Insteadof...•“Whocreatedthedefect?”ThepeoplebuildingthepartsmustbeinvolvedPRIVATE/PROPRIETARY16ErrorProofingIstheprocessof:•Anticipating•Preventing•Detectingerrorsanddefects•AnticipatingPRIVATE/PROPRIETARY17ErrorProofingistheProcessof...AnticipatingErrorsandDefectsFailureModesandEffectsAnalysis(DesignandProcessFMEA)DesignforManufacturing(DFM)&LineDesignWorkshopsStatisticalToolslikeDesignofExperiments(DOE),6Sigma,etc.Experience/HistoryPreventingErrorsandDefectsLayeringUsingRedundantMethodsCorrectingSTOP,Contain,thenFixorRemoveVerifyingConfirmtheerrorproofisworkingDesigningOne-wayassemblyDetectingErrorsandDefectsWhatProcessFeatureProductFeatureQuantityCountMotionStepWhereSource(Errors)Self(Defects)Successive(Defects)OutofProcess(Defects)WhenEveryTime100%Notifying:Stopping,Feedback,Signals(see,hear,feel,smell,taste)HowChecking/InspectingToolsPRIVATE/PROPRIETARY18WhatisAnticipation?Anticipationistheartofpredictingwhenandwhereanerrorwilloccur,suchthatitcanbeprevented.AnticipationTools:•Design/ProcessFailureModesandEffectsAnalysis(FMEA)•DesignforManufacturability(DFM)•DesignofExperiments(DOE)•SixSigmaTobecoveredinafutureclassPRIVATE/PROPRIETARY19What’sthedifferencebetween“Prevention”and“Detection”?DetectionPreventionFindserrors&defects(after)Preventserrors&defects(before)PRIVATE/PROPRIETARY20WHATisPrevention?TheintentionalactofkeepingerrorsanddefectsfromhappeningPRIVATE/PROPRIETARY21Ifthiswaspossible–verybad!PreventionPokaYokeExamplePRIVATE/PROPRIETARY22PreventionPokaYokeExamplePRIVATE/PROPRIETARY23PreventionPokaYokeExamplePRIVATE/PROPRIETARY24PreventionPokaYokeExamplePRIVATE/PROPRIETARY25PreventionPokaYokeExamplePRIVATE/PROPRIETARY26PreventionPokaYokeExamplePRIVATE/PROPRIETARY27Musthavecorrectfeatureand/orpositionofthatfeaturetoproceedI