精益生产防错

1©2003EatonCorporation.AllRightsReserved.4/11/03ErrorProofing防错2©2003EatonCorporation.AllRightsReserved.4/11/03Topics-ErrorProofingTrainingDuration时间区间Start开始时间ErrorProofing防错ObjectiveoftheTraining&Expectations0:158:00AM培训的目标及预期目的0:158:00AMWhatandWhyorErrorProofing-Exercise11:008:15AM什么是防错，为什么进行防错-练习11:008:15AMCoffeeBreak中间休息0:159:15AMApplicationofErrorProofing-OverviewExercise21:009:30AM2防错应用-总体练习21:009:30AMIdentifyOpportunitiesforErrors&PFEMA,Exercise31:0010:30AM识别防错及PFEMA良机,练习31:0010:30AMErrorProofingOptions0:3011:30AM防错方案1:0010:30AMLunchBreak午休0:4512:00PMErrorProofingOptions(continue)Exercise41:0012:45PM防错方案(续)练习41:0012:45PMActivities措施3©2003EatonCorporation.AllRightsReserved.4/11/03Topics主题ObjectivesoftheTraining培训的目的WhatandWhyofErrorProofing什么是防错，怎样进行防错ApplicationofErrorProofing防错应用IdentifyOpportunitiesforErrors防错时机的确定OverviewofFailureModeandEffectsAnalysis(FMEA)失效模式和效果分析总括ErrorProofingOptions防错的选择Prevention&DetectionThroughPokaYokeDevices通过PokaYoke进行预防与探测MovetoTheNextLevel转入下一级ABenchmarkWithinEaton伊顿内部标准Summary概要4©2003EatonCorporation.AllRightsReserved.4/11/03ObjectivesoftheTraining培训的目的UnderstandWhatIsErrorProofingandWhatItCanDo了解什么是防错和防错能做什么UnderstandthePrinciplesofErrorProofing了解防错的原理LearnHowtoApplyErrorProofingtoProductsandProcesses了解怎样对产品及工艺过程应用防错LearnAboutthePokaYokeDevicesandSystems了解PokaYoke装置和系统LearntheProcessofImplementationandContinuousImprovements了解实施防错的过程和持续改进的过程5©2003EatonCorporation.AllRightsReserved.4/11/03WhatAreYourExpectations?你们的期望是什么？6©2003EatonCorporation.AllRightsReserved.4/11/03WhatandWhyofErrorProofing什么是防错以及为什么要防错7©2003EatonCorporation.AllRightsReserved.4/11/03Definition定义ErrorProofingIsaSystematicApproachforAnticipatingandDetectingPotentialDefectsandPreventingThemFromReachingtheCustomer(InternalorExternal)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©2003EatonCorporation.AllRightsReserved.4/11/03ErrorProofingbyOtherNames以其他名称进行防错FoolProofing防止愚蠢行为IdiotProofing防止白痴行为MistakeProofing防止错误行为FailSafing安全失效PokaYokeZeroQualityControl(ZeroDefects)零质量控制（零缺陷）DesignforManufactureandAssembly制造和装配的设计LetUsNotArguetheMeritsofTheseNamesLetUsDecideWhatWeWanttoAchieve我们不要争论这些名称,让我们决定想要完成什么?DemoralizingTerms防错术语9©2003EatonCorporation.AllRightsReserved.4/11/03CharacteristicsofErrorProofing防错的特点ProactiveIdentificationandPrevention前期识别及预防PreventFirst首先进行防错DoNotAllowDefectFromGoingFurther其次不准许缺陷进一步发展IntentionallyDesigned,NotHappenstance设计错误,非偶然错误.AttheSource-ClosetotheOrigination错误的来源_接近发源地.InexpensiveFirst首先成本不高TransparenttotheOperator操作者很容易发现AbsolutelyReliable错误根源查找绝对准确AMeanstoAchieveZeroDefectProduct一种达到0缺陷产品的方法10©2003EatonCorporation.AllRightsReserved.4/11/03DefectsinProductsAretheImperfections(orFaults,orFlaws,orBlemishes,orShortcomings,orFailings,orDeficiencies)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，或者不足)ResultingFromErrors错误产生的结果ErrorsAreHumanOversights(orFaults,orBlunders,orBoo-boos,orSlip-ups,orInaccuraciesorMiscalculations)ThatCauseDefectsinProducts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失误)，这些引起产品的缺陷。DefectsandErrors缺陷和错误SO,ErrorsCauseDefectiveProducts!!所以,错误导致有缺陷的产品产生!!11©2003EatonCorporation.AllRightsReserved.4/11/03WhyAreErrorsMade为什么会导致错误AnyProductIsaResultofNumerousDecisionsMadeandActionsTakenbyHumanBeings,During:任何产品都可以在下述一系列人为行为中产生错误：ProductDesign产品设计ProcessDesign过程设计EquipmentDesign设备设计ComponentFabricationProcesses零件加工过程ProductAssemblyProcesses产品装配过程InspectionProcesses检验过程PaperworkGeneration程序行程过程Etc.等等AndHumanBeingsareFallibleorImperfect人是容易犯错或不完美的12©2003EatonCorporation.AllRightsReserved.4/11/03SOMEExamplesofDefects属于缺陷的一些例子WrongorInappropriateMaterial错误或不适合的材料WrongorNon-functioningComponents错误或者没有功能的零件WrongDimensionsorTolerances尺寸或公差错误MissingComponents零件漏装ForeignMatters,Contamination杂质物质,污秽物DamagedProductorComponents受损产品或零件WrongPaperwork,orWrongProductShipped程序错误或者运输了错误的产品Non-functioningorMalfunctioningProduct没有功能的产品或者是故障产品WrongShipping,orWrongBilling运输错误或者是填单错误13©2003EatonCorporation.AllRightsReserved.4/11/03SOMEExamplesofCausesofDefects导致缺陷的一些例子PoorDesignDecisions设计比较乏味OmittedorWrongProcessing过程疏忽或过程错误Missing/ExtraPartsorWrongParts漏装/多装了错误的零件OmittedorWrongAdjustment/Testing遗漏调整/测试或调整/测试过程错误WrongEquipmentSetuporLossofSetup设备设置错误或没有进行设备设置WrongMaterial,ComponentsorAssemblies材料，零件或者装配错误WrongCommunication,Instructions,Procedures,orMethods错误的信息，指令，程序，或者方法Inexperience,LackofTraining,WrongTraining,LackofRetraining缺乏经验，缺乏培训，培训错误，缺少再培训14©2003EatonCorporation.AllRightsReserved.4/11/03SOMEExamplesofResultsofDefects缺陷导致的结果示例MalfunctionorNon-functioningProduct有故障或者缺乏机能的产品Inconvenience,Discomfort,Injury,Death麻烦，不便，伤害，死亡Delays,Cancellations延期，取消FinancialLosses财政损失LossofUseorProductivity效用或者生产力的缺乏DamagetoCustomer’sProperty损害客户的利益LiabilitiesandLawSuites负债和法律问题LossofReputationandBusiness名誉和业务受损15©2003EatonCorporation.AllRightsReserved.4/11/03SOMECausesofHumanErrors导致人们犯错误的一些原因Forgetfulness,LossofConcentration,LackofAttentionorDivertedAttention健忘，不集中，缺乏注意力或者转移注意力Misundersta