1、MISTAKE-PROOFING 防误措施,ACE Elements,QCPC,Root Cause / Corrective Action,Passport,Mistake Proofing,Market Feedback Analysis,6S,Quality Clinic Activity,TPM,ACE 内容,质量诊断程序 图表,根本原因 修正行动,设计开发通行证,防误措施,市场 反馈 分析,6S,质量 诊断行动,全面生产性 维护,ACE Elements,Engineering New Products, Processes & Systems Passport - Systemat
2、ic method for review/approval of new designs,Standard MethodProcess Management - Means to identify & map key business processesStandard Work - Repeatable processes that are effective and efficient,Quality Improvement MethodsQCPC - Simple tool to identify problems and inefficiencies (turnbacks) MFA -
3、 Data summaries that display how components perform in fieldRoot Cause - Method to drive to the true source of problems,Standard EnvironmentNew 6S - Workplace organization and visual controlTotal Productive Maintenance - Continuously improving equipment effectiveness/availability,Mistake-Proof - Cre
4、ation of devices that ensure a task is always done correctly,ACE 内容,开发新产品、程序和系统 设计开发通行证 -检查/批准新设计的系统方法,标准方法程序管理 识别并展示重要商业程序的方法标准化作业 - 可重复的有效程序,质量改进方法质量诊断程序图表 - 识别问题和低效率（返工）的简单工具市场反馈分析 - 展示组件是怎样工作的数据摘要根本原因 - 发现问题的真正来源的方法,标准环境新6S - 工作场地组织和直观控制全面生产性维护 - 不断地改善设备的有效性和可用性,防误措施 - 确保任务总能正确完成的设备的措施,Increase
5、profitability by eliminating inadvertent mistakes 消除无谓的错误可增加利润率Increase productivity by reducing wasted time 减少浪费的时间可提高生产力Improve customer satisfaction and quality by eliminating escapes 消除逃脱可提高客户满意度和质量 Increase reliability by continuously improving products, services or processes 不断改进产品、服务或程序可提高信誉,
6、Benefits of Mistake-Proofing 防误措施的好处,They are not the same thing! Mistakes Cause Defects. 他们是不同的！ 错误导致过失,Mistakes vs. Defects 错误vs 过失,Mistake 错误,Defect 过失,Pumping diesel fuel into your gas tank. 将柴油加入汽油箱,Running a red light. 撞红灯,Forgetting to unplug your iron. 忘记拔掉电熨斗的插头,Placing the “original” in yo
7、ur copier feeder “face down”. 将原件放进了复印机的进纸处并正面冲下,or,Misunderstanding requirements 误解了要求Skipping a process step or tasks 漏掉了一个工作步骤Performing process steps incorrectly or in the wrong order 未正确地或以错误地顺序执行程序步骤Contamination 污染,Most Common Mistakes 最常见的错误,Leaving out a part or a piece of information 漏掉了一个
8、零件或一条信息Adjustment and measurement mistakes 调节和测量错误Timing mistakes 定时错误Using the wrong part, tool or information 使用了错误的零件、工具或信息,Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly. 防误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。,Mistake-Proofin
9、g 防误措施,It removes uncertainty from the situations where errors are most likely to occur, such as: 它去除了最可能发生错误的情形中的不确定性，如：Repetitive tasks 重复性的任务Complex instructions 复杂的说明书Calculations / Adjustments 计算/调节Look-alike parts 相似的零件,Why do we do Mistake Proofing? 为什么我们要采用防误措施？,To prevent turnbacks and cust
10、omer escapes from recurring, since the cost to fix a problem increases rapidly the later it is found: 为防止缺陷和客户逃脱情况再次发生，因为问题发现得越晚所花的费用就会迅速增加：,If a defect occurs here 如果在这儿发生过失,and its found here, 并在这儿被发现，it costs:就要花费：,Rework, repair, scrap and escapes cost UTC $148 million per year. Warranty expense
11、s cost us another $600 million per year. The cost of lost customer loyalty due to escapes is immeasurable. 返工、修理、废弃和逃脱每年要花掉UTC1.48亿。 保修费用每年花掉我们另外6亿。 由于逃脱而丧失了客户的信任的损失则不可计算。,Mistake-Proof 防误措施the Design 设计Redesign the product 重新设计产品 Eliminate the mistake condition 消除犯错误的条件 Redesign for symmetry or asy
12、mmetry 重新进行对称或不对称设计 Change the materials 改变材料 Change component type, characteristics or supplier 改变组件的类型、特征或供应商,2 Approaches to Mistake Proofing 预防错误的2个途径,Mistake-Proof 防误措施the Process 加工Change or add tooling 改变或增添工具Change process steps 改变加工步骤Add use of checklists, templates or gages 增加使用清单、模板或测量仪Im
13、plement control charts 执行控制图表,Process Description: Making a pot of coffee 程序描述：泡一壶咖啡,Example of Mistake-Proofing the Design 防误措施范例 设计,Before Improvement: 改进前：Water needed to be measured for each pot of coffee often resulting in coffee that was too weak or too strong泡前每壶咖啡的水量都要测量常常导致咖啡过淡或过浓。,Process
14、Description: Making a pot of coffee 程序描述：泡一壶咖啡,Example of Mistake-Proofing the Design 防误措施范例 设计,After Improvement: 改进后：Coffee maker was redesigned to measure and add the precise amount of water from a water bottle重新设计咖啡机以使每次从水瓶中加入的水的量都一样多,Process Description: A label is pasted into a recess in a mol
15、ded chassis 程序描述：将标签贴在底盘的凹槽内,Example of Mistake-Proofing the Design 防误措施范例 设计,Before Improvement: 改进前： The recess and the label were both rectangular. The label could be glued in upside-down. 凹槽和标签都是长方形。标签可能会贴反。,After Improvement: 改进后： A notch was made in the corner of the label, and in the recess o
16、f the chassis. Incorrect mounting is completely eliminated. 在标签和凹槽的一角做一个切口。就能完全防止错误发生。,Example of Mistake-Proofing the Design 防误措施范例 设计,Process Description: Install slides into a slide projector 程序描述：将幻灯片装入幻灯机中,Before Improvement: 改进前： Are some slides upside down? 有一些幻灯片装反了吗？,After Improvement: 改进后：
17、 Top edge of each slide marked with a red dot. 每张幻灯片的上边都有一红点。,Example of Mistake-Proofing the Design 防误措施范例 设计,Process Description: Torquing a number of bolts recessed deep in a cavity. 程序描述：将大量螺栓拧进空腔深处的凹槽内,Before Improvement: 改进前： The socket extension required to reach the bolts caused nicks and sc
18、ratches in the painted surfaces that it contacted during assembly. 在操作的过程中，用来拧螺栓的拧杆柄会对油漆表面造成刮伤。,After Improvement: 改进后： A rubber hose was installed over the socket extension and was specified on the work instructions. 一个橡皮管被装在拧杆柄上并在工作说明书上有详细说明。,Mistake-Proofing is a way of using wisdom and ingenuity
19、 to create devices that ensure a task is always done correctly. 防误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。,Mistake-Proofing isnt Words! 防误措施不是文字！,Word “Solution” 文字“解决方法”,Problem:The “One Day “ employee badge form asks for badge # and clock #. Employees often write their clock # in the badge # spot. 问题：
20、“一日”雇员的证件表格要求填写证件号和钟点号。雇员常将钟点号填在证件号的位置。,Badge # 证件号,Clock # 钟点号,(filled out by Emergency Services) （由紧急服务部填写）,(filled out by employee) （由雇员填写）,Guide pins or interference pins 向导图钉或干涉图钉Templates 模板Part kits using shadowboxing 使用能防止错误的零件包Limit switches 限制阀,Most Common Types of Mistake-Proof Devices 最常
21、见的防误设备,Counters 计算器Alarms 闹钟Weights and measures 称重秤和测量仪Checklists 清单Control charts 控制图表,Mistake-Proofing Process Changes 防误码程序的改变,Improve the process! 改进程序！ Simplify 简单化 Reduce steps, parts, forms, data on forms, number of process steps, etc. 减少步骤、零件、表格、表格上的数据、加工步骤的数量等。 Consolidate/Co-Locate 巩固/共用
22、Bring operations closer together, reduce work-in-process (WIP) 使操作变得更紧凑，减少过程工作（WIP） Standardize 标准化 Make the process visual 使程序可见 Move responsibility and authority down in the organization 将责任和权利下放给组织,Try-Storming (vs. Brainstorming) 尝试风暴 （对头脑风暴）Involve the right people 让合适的人参与Walk the process and g
23、et the facts 检验程序并获得事实Dont just sit and think about solutions. TRY THEM! 不要只是坐在那儿想解决问题的方法 去尝试！,Creating Mistake Proofing 创建防误措施,The “Nasty Test” (vs. the “Solution”) “恶心的试验” （对“解决方法”） When you think youve got the best solution TRY TO MAKE IT FAIL! 当你认为你已找到最佳解决方法时 试着去让它失败 Involve all users 让所有使用者参与 M
24、istake-proof devices must be 100% effective at dealing with a particular mistake 在处理特殊错误时防误设备必须100%有效 If not, they will be ignored 如果不能，就应放弃 Ensure the mistake-proof doesnt create another problem 确保防误措施不会引起其它问题,Test Mistake Proofing with the “Nasty Test” 用“恶心的试验”来验证防误措施,Formally, as part of the QCPC
25、/MFA Process 形式上的，作为QCPC/MFA程序中一部分,When do you do Mistake-Proofing 何时采取防误措施,2) Real-time, whenever you notice a mistae occurring or the potential for a mistake 实时的，无论何时你发现一个错误或有出错的可能性,There are 3 Levels of Mistake-Proofing based on effectiveness and speed: 防误措施有三个基于有效性和速度的等级：Level III: Detection等级三：
26、发现Level II: Alert等级二：警告Level I: Prevention 等级一：防止,Three Levels of Mistake-Proofing 防误措施的三个等级,Level III, Detect: Allows you to detect your Mistake after it has occurred. (1 point) 等级三，发现：在已经发生之后发现错误 Checklists 清单 Computer beeps 电脑提醒 Manually activated Spell Check 手工拼写检查 Level II, Alert: Alerts you as
27、 the Mistake is happening. (2 points) 等级二，警告：当错误正在发生时提醒你 Sensors, alarms, control charts 传感器、闹钟、控制图表 Counters 计算器 Automatic Spell Check 自动拼写检查 Level I, Prevent: Prevents you from making the Mistake. (3 points) 等级三，防止：防止你犯错误 Eliminating the mistake condition (changing the design) 消除犯错条件 Automation 自动
28、控制 Spelling “Auto-corrector” 拼写“自动更正器”,Three Levels of Mistake-Proofing 防误措施的三个等级,Mistake Proofing Qualifying Level Items 防误措施合格水平内容,The following 2 items are required to achieve the ACE Qualifying level for Mistake Proofing 要取得ACE的防误措施合格资格必须完成以下两项内容,ACE element awareness training for all employees.
29、针对所有员工的ACE内容认知培训,2. Document and post on the ACE Display Board at least 1 example of Mistake Proofing Implemented (any level.) 至少记录并张贴一个已完成的防误措施 （任何等级）在ACE展示板上,Summary 总结,Mistakes are not inevitable. 错误不是不可避免的。 A Mistake-Proof is a creative device that prevents a mistake from happening. It should be
30、: 防误措施是一项有创造性的设备能防止错误发生。它应该是： Simple 简单的 Inexpensive 不昂贵的 Reliable at preventing defects or giving prompt feedback.在防止错误或给出提示反馈时可靠的。 Mistake Proofing is critical to process improvement. 防误措施对程序改进很重要。 Necessary to achieve QCPC turnback reduction goals. 对达到QCPC减少缺陷的目标是必要的 Mistake-Proofing enhances our work environment by making it easier to do our jobs well. 防误措施通过使我们的工作更容易作好来改善我们的工作环境,
