Mistake Proof 防错培训 POKA-YOKE.ppt

Mistake Proofing Training 防错法培训 客户的要求是 100%合格的产品质量. Zero Defect Q: Do you have the sample of this kind of customer? 人的疏忽是在所难免的? 人总有疏忽的时候。 人的体力有限 人有疲劳的时候 人是有情绪的…… Q: more sample? 如何做? 设计一种防止人为的疏忽的方法,把事做得很完美.– “再笨的人也不会弄错的方法” Mistake Proofing Mistake Proofing 防错法 Poka-Yoke (POH-kah Yoh-kay) Foolproofing Mistake Proofing Difinition A poka-yoke device is any mechanism that either prevents a mistake from being made or makes the mistake obvious at a glance. Shingo System -1986 Case Study GM Sample Shigeo Sample Daily sample In office Daily sample In office Daily sample In office Daily sample In W/C Daily sample In W/C Daily sample In W/C Daily sample On the road Daily sample On the road Mistake Proofing 1)防止加工时做坏 2)防止不同产品混在一起 3)防止漏做某步加工 Mistake Proofing 基本方法 一旦有疏忽无法在治具或机器上进行组装 SAMPLE: 双手同时启动开关 Q: More ?…… Mistake Proofing 基本方法 一旦因疏忽,产生不良品时,治具或机器加工作业就无法开始,或生产停止. SAMPLE: 注塑机堵料自动停止报警. Q: More ?…… Mistake Proofing 基本方法 一旦忘了作业,不让不良品流到下一工位. SAMPLE: ASSEMBLY M/C 异形导轨 Q: More ?…… Mistake Proofing 基本方法 一旦有疏忽异品混入,无法流到下一道工位. SAMPLE: 组装机震动盘分选装置. Q: More ?…… Mistake Proofing 基本方法 一旦有不良品,不良现象时能在后工位被查出,使不良品被拦截下来. SAMPLE: ASSEMBLY M/C数针器 Q: More ?…… Mistake Proofing 手段 颜色 标线 看板 警告音 Q: More ?…… Mistake Proofing 基本方法 警告灯 治具, 夹具 检测式 半自动化,自动化 Mistake Proofing 技巧 Mistake Proofing 技巧 Mistake Proofing 技巧 Mistake Proofing 技巧 Mistake Proofing 技巧 Zero quality control: source inspection and the poka-yoke system.  Three different types of inspection Shingo identified three different types of inspection: Judgment inspection Informative inspection SPC successive checks and self-checks in ZQC Source inspection. With source inspection, poka-yoke devices ensure that proper operating conditions exist prior to actual production. Mistake Proofing SPC ZQC is not as effective as SPC for defects that result from variance in measurement data ZQC is a special case of SPC for defects that result from variance in attribute data. ZQCs source inspection can be used effectively to eliminate mi