5--errorproofing（通用汽车）

1GMCopyrightErrorProofingTechniques防错技术GMAPGlobalPurchasingandSupplyChain通用汽车全球采购及供应链管理2GMCopyright™OPENINGCOMMENTS&INTRODUCTIONS开场白及互相介绍™ERRORPROOFINGOVERVIEW防错技术概论™ERRORPROOFINGTECHNIQUES防错技术－－DFM（可制造性设计）－－Poka－Yoke（防错）－－ErrorProofingDesignandApplicationPrinciples防错设计和应用原则－－LabelErrorProofing(标签防错)™BRAINSTORMING----ProblemSolvingSolutionsUtilizingErrorProofingTechniques头脑风暴----解决问题的方案应用防错技术™DEVELOPACTIONPLANS&IMPLEMENTATION制定行动计划并实施™CLOSING&WRAP-UP总结并结束ERRORPROOFINGTECHNIQUESWORKSHOPAGENDA防错技术研讨会议程3GMCopyrightName姓名Organization在哪个部门CurrentPosition职位ExpectationofToday’sclass今天的期望Yourunderstandingforerrorproofing你对防错的理解INTRODUCTIONS互相介绍4GMCopyrightUponcompletionofthistrainingmodule,youwillbeableto培训结束，您将可以：•Definekeyconceptsoferrorproofing定义防错关键概念•Describeerrorproofingtechniqueanddifferentkindsoferrorproofing.描述防错技术及不同的防错类型•Applytheprinciplesandmethodsoferrorproofingtonecessaryworkenvironment将防错理念及方法用到必要的工作环境中WhyAreWeHereToday?--ProgramObjectives我们活动的目标5GMCopyrightTHINGSDONERIGHT99.9%OFTHETIMEMEANS...如果事情做对了99.9％即意味着…•Onehourofunsafedrinkingwaterpermonth每个月有一小时饮用水是不安全的•TwounsafelandingsatO’HareAirporteachday在O‘hare机场每天有2次不安全的降落•16,000lostpiecesofmailperhour每小时丢失16,000封信件•20,000incorrectdrugprescriptionsperyear每年有20,000个不正确的处方•500incorrectsurgicaloperationsperweek每周有500次不正确的外科手术•50newbornbabiesdroppedeachdaybydoctors每天有50个新生婴儿被医生跌落•22,000checksperhourdeductedfromwrongaccounts每小时有22,000张支票从错误的帐户扣除•32,000missedheartbeatsperpersoneachyear每人一年中有32,000次错误的心跳Problemsdescription问题描述－99.9%足够好了吗？6GMCopyrightBydesigningourproductsandprocessessothattheyminimizetheopportunityforthemistaketohappeninthefirstplace通过产品和过程设计，就能在开始时将发生错误的机率降到最低ThisiswheretheconceptofERRORPROOFINGcomesin.......这就是防错概念的来源.......ThisiswheretheconceptofERRORPROOFINGcomesin.......这就是防错概念的来源.......Iferrorsaresoeasytomake,howwillweeversendourcustomers100%goodproduct?如果这么容易发生错误，那我们怎样保证提供100%合格的产品给客户?WHATDOWEDO?我们能做什么？－客户的要求是100％合格7GMCopyright™OPENINGCOMMENTS&INTRODUCTIONS开场白及互相介绍™ERRORPROOFINGOVERVIEW防错技术概论™ERRORPROOFINGTECHNIQUES防错技术－－DFM（可制造性设计）－－Poka－Yoke（防错）－－ErrorProofingDesignandApplicationPrinciples防错设计和应用原则－－LabelErrorProofing(标签防错)™BRAINSTORMING----ProblemSolvingSolutionsUtilizingErrorProofingTechniques头脑风暴----解决问题的方案应用防错技术™DEVELOPACTIONPLANS&IMPLEMENTATION制定行动计划并实施™CLOSING&WRAP-UP总结并结束ERRORPROOFINGTECHNIQUESWORKSHOPAGENDA防错技术研讨会议程8GMCopyrightERRORPROOFINGOVERVIEW防错技术概论Whatareerrorsanddefects什么是错误和缺陷?WhydoerrorsOccur?为什么会发生错误？Whatiserrorproofing?什么是防错？Whatareprocessesoferrorproofing?防错的步骤是什么？Whatarelevelsoferrorproofing?防错的等级有哪些？Whatarebenefitsoferrorproofing?防错的益处是什么?9GMCopyrightExamplesoferrorsathome...生活中一些常见犯错的例子Runningoutofgas行驶中发现汽车没汽油了Lockingkeysinyourcar不小心将钥匙锁在车里Forgettingtostop看见停车指示却忘记停车Forgettingtoturnoffthecoffeepot忘记关掉咖啡壶的电源Forgettingtounplugtheiron忘记拔掉电熨斗插头10GMCopyrightMissingParts少装零件•Forgettingtoassembleapart-screws,labels,orificetubes...忘记装配某个零件–螺钉,标签,管子...MisassembledParts装错零件•Misassembly-looseparts,upsidedown,notaligned,e.g.-brackets(backwards),seals(notaligned),screws(loose),labels(upsidedown),...错装–零件松动,方向颠倒,不在同一水平位置,例如.–支架(前后倒置),密封条(不在同一直线),螺钉(松动),标签(上下颠倒),...IncorrectProcessing错误过程•Disposingofapartrejectedattesttothewrongpile将测试不合格的零件放入合格的产品类.IncorrectParts错误零件•Retrievingandassemblingthewrongpartfromamodelmixselection-seals,labels,brackets,cases...从混合生产线上拿错和装错零件–胶条,标签,支架,...Examplesoferrorsatwork...工作中一些常见犯错的例子11GMCopyrightCostusmoney增加成本Costustime时间损失Causeusdanger/possibleinjury给我们带来危险以及可能的伤害Lostofbusiness丢失业务ResultsofErrors错误的后果LOST12GMCopyrightErrorsareinadvertent,unintentional,accidentalmistakesmadebypeoplebecauseofthehumansensitivitydesignedintoourproductsandprocesses，错误是人们由于疏忽，无意识，偶尔犯下的差错，这是因为我们的产品和过程中还需要人的判断.Defectsaretheresultsofanerrors缺陷是错误的结果Errorsresultinthose“onceinawhile”defectsthatwealwaysfinddifficulttocontrol由于错误导致“偶尔”的缺陷让我们往往很难控制.DefinitionofErrorsandDefects错误及缺陷定义13GMCopyrightErrorsandDefects错误和缺陷DefectsaretheResults.缺陷是结果ErrorsaretheCausesofResults错误是结果的原因错误ERROR失效结果Defects车窗不能关闭座位和地毯湿了显示操作工如何正确安装零件的装置失效次品或报废品不正常的焊接速度焊接差，不合格品或报废材料14GMCopyrightWhydoErrorsOccur?为什么会发生错误？15GMCopyrightThequalityofanoperatordependentprocessisaffectedbythe：与操作者相关联的过程质量会受以下因素影响:9Knowledge(Skill)知识(技能)9Vigilance(Attentiontodetail)警惕性(关注细节)Anoperatormusthaveknowledgeofthejobinordertoknowwhattodoandwhenaqualityparthasbeenproduced操作者必须掌握他所做的工作知识，理解该做什么和什么状态下能保证质量Inaddition,aknowledgeableoperatormayhavetobevigilantwitheachpartproducedtobesureitmeetsallthequalityexpectations另外,一个合格的操作者还应该对每个加工产品保持警惕,确保它满足质量要求.}Operator操作者WhydoErrorsOccur?为什么会发生错误？16GMCopyright人的变差轮岗加班中间休息换班运输临时分派任务不同的人做同样的工作!!!!不同点:9培训的程度9整个产品的知识9客户要求的知识9工作的方式17GMCopyrightOOPS!!!!!!工作就是这样...我们今晚干什么?你认为这个新设计怎样?厌倦休息时间!!!机器停了...今晚加班?这个零件有问题....人员注意力不集中18GMCopyrightTHEERRORPROOFINGATTITUDE对防错的态度PeopleCANandWILLmakeinadvertentmistakes!人们一定会有因疏忽造成错误！Ifonepersonmakesamistake-ANYONEcan!如果一个人发生了一种错误，那么其他人也会发生！ONEmistakeoutthedooristoomany!!由于一种错误就被判出局损失就太大了!!MistakesCANbeeliminatedandMUSTbeeliminatedforustobecomeCOMPETITIVE!!!!错误能够被消除并且必须被消除，这样我们才能提高竞争力19GMCopyrightComm