MISTAKE-PROOFING 防错法.ppt

POKA - YOKE (MISTAKE-PROOFING) Introduction to workshop Lesson 1 : Outline Our responsibility Ground rules Workshop objective and scope Workshop outline This workshop and TQM Lesson 1 : Summary Defects vs. errors and Traditional Inspection Techniques Lesson 2 : Objective and purpose Lesson 2 : Outline Lesson Definitions Lesson Definitions (Contd.) Introducing Errors and Defects Error is : Not setting the timer properly on your toaster Placing the original in your copier face-up Running out of ink toner in your copier Human Errors Types of Human errors Types of production defects Traditional approach of guaranteeing quality TRADITIONAL METHOD 1 : Judgement Type Advantages and disadvantages of Judgement inspection method METHOD 2 : Informative type Advantages and disadvantages of informative inspection Lesson 2 : Summary The Poka-Yoke methodology (Steps 1 to 5) Lesson 3 : Objective and purpose Lesson 3 : Outline Are the traditional inspection techniques the strategy for Achieving Zero Defects ? ZQC Approach + Poka-Yoke Zero Quality Control has three components which lead to the elimination of defects. Introducing Poka-Yoke STEP 1 : TEAM PROBLEM DESCRIPTION STEP 2 : LOCATING DEFECTS STEP 3 : BREAKDOWN OF THEORETICAL PROCESS FLOW STEP 4 : IDENTIFYING DEVIATIONS STEP 5 : ANALYSING UP TO ROOT CAUSE STEP 5 : ANALYSING UP TO ROOT CAUSE Toolbox 2 STEP 5 : ANALYSING UP TO ROOT CAUSE Tool box 2 Lesson 3 : Summary Poka-Yoke Inspection techniques. (Steps 6 7) Lesson 4 : Objective and purpose Lesson 4 : Outline What is a Poka-Yoke device ? Why do we need Poka-Yoke devices ? What is a Poka-Yoke device ? Why do we need Poka-Yoke devices ? Types of Poka-Yoke devices. A Poka-Yoke device must be combined with one of the following three (3) inspection systems :- SOURCE INSPECTION SYSTEMS Inspection at the input parameter stage INFORMATIVE INSPECTION SYSTEMS - SELF CHECK Inspection at the output parame