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1、1,Poka-Yoke防错法,2,内容简介,基本概念防错措施防错举例,3,一.基本概念,4,背景介绍,5,背景介绍,Poka-yoke 发音为“poh-kah yoh-kay”译为避免 yokeru由于疏忽造成的错误poka,英语同义Mistake-proof,中文译为波卡纠偏,Poka-Yoke:一种改进工具,技术和过程的方法,可以在错误变成缺陷前防止或检测它安排订单的事例是提高订单输入从传统方式转向其它方式的一个透视窗口。出现疑问的订单再次被核对，经常发现输入差错或由于错误信息而导致的购买差错。生产的事例是沿着装配线集装箱上的一套光电池部件，以防止进入下一阶段时缺少零件,6,7,Shige
2、o Shingo 的3种形式的检验,判断检验 发现缺陷（不是最希望的-缺陷发生很长时间后的质量检验）通知检验 降低缺陷（对从过程中得出的事实和数据，加以控制）三种类:统计质量控制体系连续检验体系自检体系源头检验 去除缺陷（产品产出以前）两类:垂直源头检验水平源头检验,好的办法是将生产和检验同时进行,有效的poka-yoke设备建立生产/检验的体系，以减少检验时间和成本，使之趋于零,8,Increase profitability by eliminating inadvertent mistakes消除无谓的错误可增加利润率Increase productivity by reducing w
3、asted 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,Benefits of Mistake-Proofing防错措施的益处,9,They are not the same thing!Mistakes Cause Defects他们是不同的！错误导致缺陷,
4、Mistakes vs.Defects 错误vs 缺陷,Mistake错误,Defect缺陷,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 your copier feeder“face down”.将原件放进了复印机的进纸处并正面冲下,or,10,Misunderstanding requirements 误解了要求Skipping a process step or
5、 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
6、具或信息,11,二.防错措施,12,Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly防错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防错措施,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
7、确定性例如：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,13,1-10-100 Rule,1-10-100 规则说明了一个产品或服务在它的生产流程中前进时改正一个错误的成本将会十倍增加活动 成本 正确操作程序$1在生产时检测到错误$10客户检测到错误$100不满意的客户还会和其他的客户分享经验的成本,$1000,14,Why do we do Mistake Proofing?为什么我们要采用防错措施？,To prevent t
8、urnbacks and customer 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,If its found here,如果在这儿被发现，it costs:就要花费：,Rework,repair,scrap and escapes cost UTC$148 million per year.Warrant
9、y expenses 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,15,Mistake-Proof 防错措施-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
10、asymmetry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 防错措施-the Process 制造过程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Impleme
11、nt control charts执行控制图表,16,Process Description:Making a pot of coffee程序描述：泡一壶咖啡,Example of Mistake-Proofing the Design防错措施范例-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,17,Process Descr
12、iption:Making a pot of coffee程序描述：泡一壶咖啡,Example of Mistake-Proofing the Design防错措施范例-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,18,Process Description:A label is pasted into a recess in a molded cha
13、ssis程序描述：将标签贴在底盘的凹槽内,Example of Mistake-Proofing the Design防错措施范例-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 of the chassis.In
14、correct 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。,19,Example of Mistake-Proofing the Design防错措施范例-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：Top edge of each slide
15、 marked with a red dot.每张幻灯片的上边都有一红点。,20,Example of Mistake-Proofing the Design防错措施范例-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 scratches in the painted surf
16、aces 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,21,彻底落实三不政策:1)不接受不良品 2)不制造不良品 3)不流出不良品,制造过程防错的基本观念,22,1)以全数检查代替抽样检查 2)以设备检查代替人工检查作业内容必须在
17、设备上设置检查机构，以强制人员依标准程序执行随时检查生产条件与防错设备是否失效,并以设备条件禁止作业者调整或变动,制造过程防错的基本手法,23,不良品的防错手法,单站作业防止漏、误组 1.使用ROBOT或专用设备：以设备内的程序控制器执行防错组措施 2.使用SPOT COUNTER：在漏焊的状况下提前检知并以停止、干扰、警示方式通知作业者；另外，SPOT COUNTER要求安装于GUNSHANG上，避免因距离太远而降低其警示的效果 3.不良品发生时，厂商必须建立正确的排误标准 例如：A：由组长排除错误，不得由作业员私自操作 B：漏焊时，补焊动作必须于该站上立即改善完成（包含部 品改善及制程防错
18、失效确认），不得事后才整修,24,各站连动作业防止漏、误组 1.使用ROBOT专用设备：以各站间连动的程序控制器执行防错组措施 2.前一站制作的半成品必须经设备确认制作完成后，才可投入下一站 若未经确认完成，设备必须停止或设置干扰投入下一站的机构 3.部品未全部生产完成前，设备必须发出警示或干扰讯息阻止人员 开作业区，直至生产完成,不良品的防错手法,25,不良品不流出的防错手法,收料防错确认 1.未经设备确认部品生产合格前，阻止物料投入料架（以盖板、网 横杆阻止投料)2.生产完成后，以设备强制全检，并由设备投入或判别是否投入料架,26,料架防错功能追加对应种别加工物料，必须针对种别部位设置立即
19、检查机构，错件无法放入1.外型定位：料篮（或料架）内设置固定外型的插槽，物料投入时，错件无 法投入或可立即辨认投入错误2.强制检查：补给单位提供料架时，已将料架检查PIN（或检查杆）安装于 料架上，让料架针对物料执行全检,不良品不流出的防错手法,27,制造过程防错系统的管理,不良回馈与处置 投入未定位或缺误件时，设备将通知停止生产，直到不良全部排除为 止。设备通知停止生产讯息：A.停止：设备停止作动（最佳）B.干扰：以装置干扰生产（次佳）C.警示：蜂鸣器、警示灯、警示标志（最差）防错机构的失效防止管理 1.以品质状况追踪：以首、中、末检查记录，追踪防错装置是否失效 2.以设备侦测追踪：设备自动
20、侦测失效并立即反映失效（在ROBOT程式中有此类侦测功能）3.以人员与计划表追踪：透过计划时程（例：每天的始业点检），以不 良品确认机构是否失效,28,Mistake-Proofing isnt Words!防错措施不是文字！,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：“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,29,
21、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最常见的防错设备,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,30,Mistake-Proofing Process Changes防错误程序的改变,Improve the process
22、!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Bring operations closer together,reduce work-in-process(WIP)使操作变得更紧凑，减少在制品（WIP）Standardize 标准化Make the process visual 使程序可见Move responsibility and authority down i
23、n the team将责任和权利下放给团队,31,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 get 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创建防错措施,32,The“Nasty Test”(vs.the“Solution”)“恶心的试验”（对“解决方法”）When y
24、ou 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Mistake-proof devices must be 100%effective at dealing with a particular mistake在处理特殊错误时防错设备必须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确保防错措施
25、不会引起其它问题,Test Mistake Proofing with the“Nasty Test”用“恶心的试验”来验证防错措施,33,1)Formally,as part of the QCPC/MFA Process 形式上的，作为QCPC/MFA程序中一部分,When do you do Mistake-Proofing何时采取防错措施,2)Real-time,whenever you notice a mistake 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,34,There are 3 Leve
26、ls of Mistake-Proofing based on effectiveness and speed:防错措施有三个基于有效性和速度的等级：Level III:Detection等级三：发现Level II:Alert等级二：警告Level I:Prevention等级一：防止,Three Levels of Mistake-Proofing防错措施的三个等级,35,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
27、 清单Computer beeps 电脑提醒 Manually activated Spell Check 手工拼写检查Level II,Alert:Alerts you as 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)等级一，防止：防止你犯错误E
28、liminating the mistake condition(changing the design)消除犯错条件Automation 自动控制Spelling“Auto-corrector”拼写“自动更正器”,Three Levels of Mistake-Proofing防错措施的三个等级,36,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:防错措施是一项有创造性
29、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.防止错误或给出提示反馈时可靠的。Mistake Proofing is critical to process improvement防错措施对程序改进很重要Necessary to achieve QCPC defects 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防错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,37,三.防错举例,38,39,40,41,42,
