Error ProofingTechniques防错技术GMAPGlobal Purchasing and Supply Chain通用汽车全球采购及供应链管理PDF 文件使用 "pdfFactory Pro" 试用版本创建
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍－－Introductions相互介绍－－Why Are We Here？我们的活动目的。－－Problems description 问题描述vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术－－DFM （可制造性设计）－－Poka－Yoke （防错）vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
INTRODUCTIONS互相介绍Name姓名Organization在那个部门Current Position职位Expectation of Today’s class今天的期望Your understanding for error proofing你对防错的理解PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww Bw .
Why Are We Here Today?--Program Objectives我们活动的目标Upon completion of this training module, you willbe able to培训结束，您将可以：•Define key concepts of error proofing 定义防错关键概念•Describe error proofing technique and different kinds of error proofing.描述防错技术及不同的防错类型•Apply the principles and methods of error proofing tonecessarywork environment将防错理念及方法用到必要的工作环境中PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Problems description问题描述－% 足够好了吗？THINGS DONE RIGHT % OFTHE TIME MEANS . . .如果事情做对了％即意味着…•One hour of unsafe drinking water per month每个月有一小时饮用水是不安全的•Two unsafe landings at O’Hare Airport each day在O‘hare机场每天有2次不安全的降落•16,000 lost pieces of mail per hour每小时丢失16,000封信件•20,000 incorrect drug prescriptions per year每年有20,000个不正确的处方•500 incorrect surgical operations per week每周有500次不正确的外科手术•50 newborn babies dropped each day by doctors每天有50个新生婴儿被医生跌落•22,000 checks per hour deducted from wrong accounts每小时有22,000张支票从错误的帐户扣除•32,000 missed heartbeats per person each year每人一年中有32,000次错误的心跳PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
WHAT DO WE DO?我们能做什么？－客户的要求是100％合格If errors are so easy to make, how will we ever send our customers 100% good product? 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?By designing our products and processes so that they minimize the opportunityfor the mistake to happen in the first place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TThhis is where the concept of is is where the concept of EERRRROORR PROOFING PROOFINGccoommeess in.......这就是防错概念的来源....... in.......这就是防错概念的来源.......PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍－－Introductions相互介绍－－Why Are We Here？我们的活动目的。－－Problems description 问题描述vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术－－DFM （可制造性设计）－－Poka－Yoke （防错）vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
ERROR PROOFING OVERVIEW防错技术概论What is error proofing？Key concepts.什么是防错? 关键概念What are the benefits of error proofing?防错有哪些益处？When should we use ErrorProofing？何时使用防错？Other Titlesof Error Proofing防错的其它术语PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing ---KeyConcepts关键概念�What are errors and defects?什么是错误，什么是缺陷？�What are the results of errors?错误的后果是什么？�Why do errors happen?错误的根源是什么？�What is error proofing?防错的定义PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Definationof ErrorsandDefects错误及缺陷定义Errors are inadvertent, unintentional, accidental mistakes made by people because of the human sensitivity designed into our products and processes，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.Defectsarethe resultsof an errors缺陷是错误的结果Errors result in those “once in a while”defects that we always find difficult to control由于错误导致“偶尔”的缺陷让我们往往很难控制.PDF 文件使用 "pdfFactory Pro" 试用版本创建
Examplesof errors at home. . .生活中一些常见犯错的例子Running out of gas行驶中发现汽车没汽油了Locking keys in your car不小心将钥匙锁在车里Forgetting to stop看见停车指示却忘记停车Forgetting to turn off the coffee pot忘记关掉咖啡壶的电源Forgetting to unplug the iron忘记拔掉电熨斗插头PDF 文件使用 "pdfFactory Pro" 试用版本创建 Àw
Examplesof errors at work. . .工作中一些常见犯错的例子Missing Parts少装零件•Forgetting to assemble a part -screws, labels, orifice tubes...忘记装配某个零件–螺钉, 标签, 管子...Misassembled Parts装错零件•Misassembly-loose parts, upside down, not aligned, . -brackets (backwards), seals (not aligned), screws (loose), labels (upside down), ...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),...Incorrect Processing错误加工•Disposing of a part rejected at test to the wrong pile将测试不合格的零件放入错误的产品类.Incorrect Parts错误零件•Retrieving and assembling the wrong part from a model mix selection -seals, labels, brackets, cases...从混合生产线上拿错和装错零件–胶条, 标签, 支架,...PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Results of Errors错误的后果Cost us moneyLOST增加成本Cost us time时间损失Cause us danger/possible injury给我们带来危险以及可能的伤害Lost of business失去业务PDF 文件使用 "pdfFactory Pro" 试用版本创建
Why do Errors Occur?为什么会发生错误？The quality of an operator dependent process is affected by the：与操作者相关联的过程质量会受以下因素影响:�Knowledge(Skill)知识(技能)�V}Operatorigilance(Attention to detail)操作者警惕性(关注细节)An operator must haveknowledgeof the job in order to know what to do and when a quality part has been produced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In addition, a knowledgeable operator may have to bevigilant with each part produced to be sure it meets all the quality expectations另外, 一个合格的操作者还应该对每个加工产品保持警醒,确保它满足质量要求.PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
WHAT IS THE ROOT CAUSE?错误的根源是什么？People make errors人们是会犯错误的An error becomes a defect only if it is not detected prior to processing如果在加工之前没有被发现，错误就会演变成缺陷（产品）。Have devices—not people—perform 100% inspection通过设备－而不是人－执行100％检查Inadvertent errors are not only possible,but inevitable.无意识的错误不仅仅是可能的而且是不可避免的。PDF 文件使用 "pdfFactory Pro" 试用版本创建 Âw
Definition of Error Proofing防错技术的定义Error Proofing is a process of:Anticipating, detecting, and preventingerrors and defectswhich adversely affect customers and result in waste.防错技术是预见、探测和防止错误和缺陷的方法，这些错误和缺陷会给顾客带来不良影响并造成浪费。It usesdevices or inspection techniques thatdetect errors during the work process rather than at the end of it.防错是使用探测技术或装置在加工过程中发现错误，而不是到最后一刻。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
What are the benefits of error proofing?防错的益处是什么？Minimize or eliminate waste.减少或消除浪费Reduce cost of waste,降低浪费代价，scrap, rework.降低废品率，减少返工Reduce cost of end of line checking fixtures.降低终检的检验成本Meet or exceed goal(s)达到或超越:“Zero Defects.”0缺陷目标PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±wwÿw .
When should we use ErrorProofing何时使用防错In instances when product or process designs have not ensured customer satisfaction, ErrorProofing action is required in the manufacturing and / or assembly process.当产品或过程设计不能确保顾客满意的时候，就需要在生产或装配中加以实施防错。Error Proofing is designed to help us eliminate defects by enabling us to implement design features,manufacturingmonitoring devices, and production controls that will assure error free products to the customer.防错是通过应用产品特征、制造监控装置以及产品控制等方式来帮助我们消除缺陷，确保所生产的无缺陷产品送至顾客。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Other Titlesof Error Proofing防错的其它术语Error Proofing防错Fail-Safeing失效预防Fool-Proofing防呆Mistake-Proofing防错Poka-Yoke防错PDF 文件使用 "pdfFactory Pro" 试用版本创建
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍－－Introductions相互介绍－－Why Are We Here？我们的活动目的。－－Problems description 问题描述vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术－－DFM （可制造性设计）－－Poka－Yoke （防错）vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Error Proofing Techniques防错技术•Design for Manufacturability可制造性设计Techniques that results in designs that cannot be incorrectly manufactured or assembled, which also simplifies the design and reduces its’cost这种技术把产品设计成不能被错误地制造或装配，这也简化了设计，并降低成本。•Poka-Yoke System Devices防错装置Setup devices or inspection techniques that ensure setup is donecorrectly. The basic functions of a Poka-Yoke system are:* Control (shutdown)* Warning* Identification通过设定好的设备或检测技术来确保正确执行操作。防错装置的基本功能有：×控制（停线）×报警×识别PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Levels of Error Proofing防错技术等级Defect AvoidanceNTraining/ o Visual Containment*DetectionRobust Product/ CInstructionVisualontrolsControls可100% InspectionStops Process Designs无控制作业指导Aids培训视化控制遏制100％检验ProcessAutomation/图示说明缺陷探测预防－－稳健产停线品/工艺设计自动化Awareness告知Detection探测Prevention预防PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing Techniques防错技术To achieve a robust system, implement Error-Prooftechniques in the Process Design stage.为获得稳健系统，在过程设计阶段采用防错技术A robust process is one that is consistently capable of high productivity at high quality over extended periods. It is ideally incapable of producing defects. Webster defines robust as “full of health and strength.”稳健过程是指在相当长的时间里，能够持续获得高生产率和高质量的能力。也就是不可能制造缺陷产品的能力。A robust process requires:稳健过程要求：•Continuous improvement持续改进•Cost-effective solutions经济适用的解决方案•Error－Proofing techniques防错技术PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
•Poka-Yoke”System*•Poka-Yoke系统“Poka-Yoke”System*Poka-Yoke系统Set-Up Devices or Inspection Techniques that Assure that Set-Up is Done Correctly; . Produces 100% Good Parts from the First Piece on设定装置或检测方法从而保证操作前设定正确，即从第一件起就确保生产出100％合格的零件“Zero Quality Control: Source Inspection and the Poka-Yoke System”-Shigeo Shingo; 1986PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing Components--Detection Methods防错法组成要素--探测方法Detection Methods探测方法•Feature特性检查•Count计数检查•Motion-step次序检查CheckingMethods检验方法Error Proofing•Judgment判断法Deviceor •Informative–SuccessTechniqueive后续检验法–Self自检法防错设备•Source来源法/技术Feedback Type反馈方法•Warning警告法•Control/Halt控制/中断法PDF 文件使用 "pdfFactory Pro" 试用版本创建
DetectionMethod探测方法Feature Checking Method特性检查法Definition:A method for checking the physical characteristics of a part or process to differentiate it from a standard.定义：检查产品或过程特性与标准之间差别的方法。Types of FERROReatures特性种类PROOFINGPROCESSProcess过程Product产品PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Process Features过程特性What is a Process Feature?什么是过程特性？Process Feature Examples例如:•Air pressure 空气压力•Temperature 温度•Time时间•Anything that affects the process任何影响过程的参数How do we implement a Checking Method on a Process Feature?如何对过程特性进行检查？Checking Method examples例如:•Air pressure gages空气压力表•Electronic gages电子表•Sensors传感器PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
PFrocess Features过程特性eature Checking MethodTorque Example 扭距Torque ExampleFeedback lightsTorque readoutPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Proodducut cFetaFtuereast产u品re特s性产品特性What is a Product Feature?什么是产品特性No GoProduct Feature Examples例如:•Size 尺寸•Inside diameters内径•Thickness厚度•Color颜色How do we implement a Checking Method on a Product Feature?如何对产品特性进行检查Checking Method examples例如:•Sensors传感器•Electrical reading devices电子读取设备NAME PLATE•Locator pins定位销•Assembly jigs装配夹具PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
PDertoecdtiuonctMeFtheoadtures产品特性Seatbelt One-Way Assembly ExampleRight hand locator tabLeft hand locator tabPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Detection Method 探测方法Count Checking Method计数检查法Definition:A method that incorporates countingthe number of parts per assembly or the number of tasks to complete an operation.定义：检查装配时的零件数量或完成某个操作时的任务数量。Count Checking Method Examples例如:Torque Confirm•Click wrenches扳手的咔哒声•Kitting (packaging parts of an assembly)套装法（按每次装配所需的零件包装）•Counting the number of bolts on an assembly在每次装配时清点所需螺栓数量Hood bolt kit4 eachPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
CDoeutnet Cchtieocknin Mg Meetthodd 探测方法Click Wrench ExampleCount wrench clicksLimit switch feedback wirePDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
DCoeutnet cCthecking Methodion Method 探测方法Count Back ExamplePDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
DDeettecctitoinoMne tMhoedthod 探测方法探测方法Motion-step Checking Method次序检查法Definition:a method in which defects are detected by checking for errors in sequenceof operations or elements. This applies to operations that must be carried out with pre-determined motions or critical sequence.定义：检查由于操作次序错误而造成的缺陷。该方法应用于必须按照预定的动作或次序进行操作的工位。Motion-step Checking Method Examples例如5:•Lapped parts零件层叠23•Fasteners needing to be tightened in a particular 紧固件需按规定的次序拧紧6PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing Components---CheckingMethods防错法组成要素--检验方法Detection Methods探测方法•Feature特性检查•Count计数检查•Motion-step次序检查CheckingMethods检验方法Error Proofing•Judgment判断法Deviceor •InformativeTechnique–Successive后续检验法–Self自检法防错设备•Source来源法/技术Feedback Type反馈方法•Warning警告法•Control/Halt控制/中断法PDF 文件使用 "pdfFactory Pro" 试用版本创建
Error-Proofing Checking Method CheckingMethods检验方法Judgement判断检验法Judgement Inspection Method判断检验法What are some drawbacks?缺点是什么？Provides littleor no feedbackto the operator.极少或没有给操作人员提供反馈Does not occur in-station不能在操作岗位进行Incorporates end-of-lineinspection需要结合终检执行PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
EErrrroorr--PPrrooooffiinngg Chheecckkiinngg Meetthhoodd 检JJuu验ddgge方meem法nte Innstp判ect断ion检 M验eth法od判断检验法•End-of-lineinspectionCheck终检•Maycatch defectspriorF teoe dbackDefectshipment可能会在发运前发现缺陷Error•Weak feedback to upstream processes对上道工序反馈极少PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
EJrurdogre-mPernoofing Checking Method t InspectionsJ判u断dg检e验m法ent判断检验法DODO NOT♦Help prevent some ♦Reduce defect rates in the defective goods from plant降低不合格品率reaching subsequent ♦Improve the manufacturing processes帮助防止一些不合格品process改进制造工艺流入下道工序♦Reduce production costs♦He降低生产成本lp prevent some defective goods from ♦Provide immediate feedback reaching the customerfor swift corrective action帮助防止一些不合格品为快速纠正措施提供及时反馈流入客户PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Error-Proofing Checking Method SInufocrcmeastisve Inspection Method信息检验法ive Inspection Method后续检验法Successive Inspection Method后续检验法Definition:An inspection that is performed as close as possible downstream of the operation; this method also provides a feedback loop to the error or defect origin.定义：在尽量靠近该工序的下道工序进行检验，并同时对发现的缺陷提供反馈。DownstreamFlowUpstreamPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method Informative: Successive Inspection后Su续c检c验es法sive Inspection Method后续检验法CheckFeedbackDefectErrorTouch or use marker to highlight completed operation用记号强调完成的操作Follow process inspections跟踪过程检验Inform the previous process of defect将发现的缺陷通知前道工序Defect reduction depends on problem solving skills 缺陷的减少取决于解决问题的技能。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method SSuucccecsesisves iIvnesp Iencftoiornm Maettivheod I后ns续p检ec验ti法on MethodBrake Line ExampleTeam member tightens fastener on brake line制动生产线紧固螺栓PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method SSuucccecsessivse Informative Inspection Methodive Inspection Method后续检验法Downstream Inspection Example•Torque wrench dipped in yellow paint扳手沾黄色漆•Fastener inspected for paint mark in successive operation螺母检验者在后续工位中检验油漆标示PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method SSuuccessive Informative Inspection Methodccessive Inspection Method后续检验法Verification Station–Check for Yellow Paint验证岗位—检查是否有黄色漆标示PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method Informative: Self-Inspection自检Self-Inspection自检Definition:An inspection method that is done in-station and provides immediate feedback.定义：在操作工位上执行并能够及时提供反馈的检验方法•Inspect own work检查自己的工作•Receive immediate feedback立刻得到反馈Check•Enable instant corrective action 能够立刻采取纠正措施•Improve ability to root cause problem改进问题的根本原因FeedbackDefectErrorPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method Source Inspection Method来源检验法Detect error before processing在加工前发觉错误Use error detection device(s)使用错误探测设备Provide feedback at the error stage在错误阶段提供反馈CheckStopprocess before errorbecomes a defect在错误变成缺陷前停止加工FeedbackDefectsErrorActionCheck FeedbackPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method SSoouurce Inspection Methodrce Inspection Method来源检验法Rack and Pinion Sub-assembly ExampleWork station clamps andlocks sub-assembly in place工位夹钳夹住并锁住分总称Clamps unlock if fasteners are tightened to specification在紧固件紧固到要求值后夹钳才能打开PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Checking Method SHiuerbar－chys oufm Insmpeaction Techniques检验法的层次ry 小结•Detect errors in-station在操作工位发觉错误Soufects prevented）缺陷预防rce(de法One-way assembly单一的状态方–Detect motion探测动作•Operator inspects workS操作工检验elf(defects detected)缺陷探测–Andon暗灯–Color code色码Success•Inspect at following process ive下道工序检验(defects detected)缺陷探测–Paint mark油漆记号–Touch接触PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing Components---Feedback Type防错法组成要素---反馈方法Detection Methods探测方法•Feature特性检查•Count计数检查•Motion-step次序检查CheckingMethods检验方法Error Proofing•Judgment判断法Deviceor •Informative–SuccessTechniqueive后续检验法–Self自检法防错设备•Source来源法/技术Feedback Type反馈方法•Warning警告法•Control/Halt控制/中断法PDF 文件使用 "pdfFactory Pro" 试用版本创建
Error-Proofing Feedback Type F反ee馈dba类ck型 Type反馈方法Warning Correcting Method警告纠正法Informs the operator that an error or defect has just occurred.当错误或缺陷发生时，立刻通知操作工Uses audible alarms.使用声音警告•., sirens, horns, bells 如：警报器、喇叭、铃声Uses visual alarms.使用目视警告•., flashing lights, indicator boards如：闪光的灯、指示器板PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Feedback Type C反or馈rec类ting型 MethodWarning ExampleWarning LightPDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Feedback Type Feedback Type反馈馈方法类型AControl/Halt Correcting Method控制/停止纠正法DefectsInterlocks with the process与过程互锁•Halts the process停止过程Requires operator interaction with the defect需要操作工对缺陷进行处理•Operator must correct or seeksupport操作工必须纠正或寻求支持•Process is ready to continue after the solution is implemented过程在问题解决后才能继续PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error-Proofing Feedback Type F反ee馈dba类ck型 Type反馈方法Caution注意When using a Control/Halt Correcting Method, always include a Warning Correcting Method.当使用控制/停止纠正法时，一定要包含警告纠正法。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍－－Introductions相互介绍－－Why Are We Here？我们的活动目的。－－Problems description 问题描述vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术－－DFM （可制造性设计）－－Poka－Yoke （防错）vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
ERROR PROOFING TECHNIQUES--Label Error Proofing防错技术---标签防错PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Label Error Proofing标签防错What is Mislabeling/Why is it a big deal?什么是贴错标签/为什么它是一个严重问题？The Disciplined System规范化体系Types of Labels标签的种类Mislabeling: Causes and Preventive Methods贴错标签：原因及预防方法PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Label Error ProofingWHAT IS MISLABELING? 什么是贴错标签？PARTS AND LABEL DO NOT MATCH零件和标签不匹配Mismatch匹配错误Shipping Label发运标签OtherWrong part numberng sequence零件号错误WWrorong destination 排序错误W错误的目的地rongIncorrect quantity hand左右件错误Wrong engineering数量不正确change levelWMixed containersrong color颜色错误错误的工程更改等级on palletUnreadable bar code M铲板上包装箱混放ixed parts零件混装无法读取的条形码Wrong part Missing labelidentificationPartial container零件名称错误包装箱未装满标签遗失。。。。。。Foreign parts不相关零件PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Label Error Proofing标签防错Mislabeling: Atop quality issue贴错标签：主要的质量问题Mislabeling is one of the top quality issues throughout General Motors and the auto industry.贴错标签是普遍存在于GM及其他汽车公司的主要的质量问题之一Due to mislabeling, thousands of perfect parts are rejected and sent back to suppliers every day.由于贴错标签，每天有上千的合格零件被拒收并返还给供应商PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Label Error Proofing标签防错ASSEMBLY PLANT DISRUPTION装配线中断Typical Assembly Plant典型的装配厂Lean Demands精益生产需要1 Vehicle Built Per Minute每分钟生产1辆车1,000 Vehicles Built Per DaySmaller Containers较小的包装箱每天生产1,000辆车3,000 Part Numbers Per Vehicle每辆车上有3,000种零件Less Inventory减少库50 Parts Per Container存每个包装箱里有50个零件60,000 Containers Per Day每天使用60,000个包装箱Smaller Containers = More Labels / More Opportunities for Errors较小的包装箱=更多的标签/更多的出错机会Less Inventory = More Disruption When Parts Are Wrong减少库存=零件出错时将会造成更大的中断ONE mislabeling incident is too many一个标签贴错的代价是非常之大PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Mislabel Impact to NAVO Assembly Plants贴错标签对北美装配厂的影响What does labeling have to dowith Zero Tolerance?贴标签与零容忍度有什么关系?2003 NAVO Assembly PlantsLabelingRelated Incidents2003年北美装配工厂与贴标签相关的事故5% of all PRRs18% of all spills2003ZERO TOLERANCE THINKING APPLIES TO ALL PRRs INCLUDING LABELING PRRs1,955 零容忍度理念适用于所有的PRRLabeling PRRs包括与贴标签相关的PRR PDF 文件使用 "pdfFactory Pro" 试用版本创建
GM DIRECTION ON MISLABELINGGM公司在贴错标签问题上的规定GM Issued Two Bulletins Stating Their Mislabeling Policy Bulletin1435 Dated May 16, 2001 and Bulletin 4118 Dated May 7, 2003GM公司曾两次在公告栏发布贴错标签政策,分别为2001年5月16日1435号公告和2003年5月7日4118号公告Effective immediately, any supplier that has a labeling error will be placed into Controlled ShippingIIand be required to host a Label Error Proofing Workshop任何供应商只要发生标签错误立即对其执行2级受控发运并需强制执行标签防错培训Exit criteria for Controlled Shipping Level II2级受控发运的退出条件�The 3rdparty workshop provider shall verify the implementation of Label Error Proofing Devices (bar code scanning equipment or equivalent) on the specific product line in a required follow-up visit必须由第三方培训者在特定的生产线上跟踪核实标签防错设备(条形码扫描设备)的执行情况�Supplier administered layered audits shall be implemented to ensure the labeling process is being followed在供应商实施现场层级评审中必须包含确认贴标签程序的执行情况�Strategies and action plans shall be developed for label error proofing the entire manufacturing facility. For those product lines where label error proofing isnot fully implemented, containment or temporary countermeasures shall be in place.必须对整个生产线实施针对标签防错的对策分析及整改计划.对那些不能充分实施标签防错系统的生产线,必须实施围堵政策或其他临时对策�Zero label incidents for 90 consecutive working days after irreversible corrective action has been implemented纠正措施执行后连续90天无标签事故发生PDF 文件使用 "pdfFactory Pro" 试用版本创建
Label Error ProofingWhat can you do?你能做些什么?Recognition of elements required to eliminate mislabeling errors识别消除贴错标签错误必需的要素Keys to a disciplined system规范化体系的关键所在PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
As the expert on your system, you should...作为专家,你应该…Communicate your goal 沟通你的目的Involve all team members 让所有的成员都能参与其中�Identify opportunities for mislabeling识别贴错标签的可能性�Approach your current system from a new perspective 从新的视角,探究现存的体系�Track and Implement action items during trouble shooting activity在解决问题过程中,跟踪并执行相应的整改措施PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
you should...你还应该…Supply all team members with documentation of new techniques为所有的小组成员提供与新技术相关的文件Include a separate PFMEA for labeling 为贴标签提供专门的PFMEAHighlight labeling areas within the PCP在控制计划中重点标出贴标签的部分Words are only words until you put them in action—only then do they become success stories承诺只是承诺,只有当你把诺言付诸行动时,它们才会成为成功的案例PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Change Your Mindset改变你的想法If you always do whatyou always did,then you’ll always get what youalways got.如果你总是按你过去的方式做事,那么你只会得到与过去相同的结果PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Zero Parts Per Million (PPM) and Zero-Defect Quality0 PPM和0质量缺陷GM’s Goal is a zero-defect productGM的目标是零缺陷产品Cutting mislabeling occurrences to zero requires setting goals将贴错标签发生率降到零,需要建立目标Achieving those goals requires improving every facet of the process完成这些目标需要考虑改进过程中的各个方面PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Label Error ProofingKeys to a Disciplined System规范化体系的关键所在Discipline does not rely on the operator; it is a built-in part of the system.标签规则不应依赖于操作工,而应该是体系的一部分PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Label Error ProofingIdentify Labeling System Components识别标签系统的组成Review types of labels讨论标签的种类Explain how mislabeling occurs解释贴错标签是如何发生的PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Labeling System Consists of...标签系统的组成GM 1724-A labelGM 1724-A标签Part container零件包装箱MGO signal原材料全球最优化信号WIP label在制品标签PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
WHAT IS THE GM 1724-A LABEL?Encoded 2D Bar Code DataCusPart #, Qty, License Plate,tomer address,PPlant/Dock, Mat’l Handling codelant & delivery dockFROMTOSupplier DataGENERAL MOTORS CORPORATIONSUPPLIER ID: 3396676ORION ASSEMBLY PLANTLAKEVIEW PRODUCTSLAKE ORION, MI 48359ANYWHERE, MIPLANTDOCKLC 15CQUANTITYMATERIALHANDLINGCODEREFERENCE160A6-987G1155Delivery locationPARTWNUMBERithin the plant12345678PACK DATE:LICENSEPLATE(1J)20APR2000SuppCONTAINER TYPE:lier Duns ID& ShipPackKLT3214 serial #UNGROSSWEIGHT:123456789A2B4C6D8E10KGPCI segments from EDIPCI segments from EDIL F BHD -CH BRPCI segments from EDISupplier defined areaDeliverylocation on the linePDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Dependent Labels非独立标签Dependent labels depend on a separate source of identification to attain an absolutely certain match with a part. 非独立标签需要依赖于另一种的识别源来共同完成与零件的匹配4Sample board样品板4Visual display目视管理4E睛xperienced eye有经验的眼PDF 文件使用 "pdfFactory Pro" 试用版本创建 fwfw
Independent Labels独立的标签The part is easily matched to its associated label:零件可以轻而易举地与其对应的标签匹配:nMarkings can be readily identified on the label标签上的标记很容易识别nNo separate tools needed to accomplish the match无需另外的工具即可完成匹配nAudits for labels can be performed by anyone at any time任何人在任何时候都可以对标签系统实施审核nIndependent labels help reduce errors独立标签有助于减少错误PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Labeling is Simple贴标签是简单的Labeling is a 2-second operation that frequently has no detection/inspection system.通常贴标签是在2秒种内完成的动作,而不包含任何探测/检查系统Because labeling is a simple process, we don’t anticipate problems. But often, we underestimate possibilities for errors to occur. 正是由于贴标签是一个简单的过程,我们就不去预测可能发生的问题.然而,通常我们低估了其出错的可能性PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
How Does Mislabeling Occur?贴错标签是如何发生的?A mismatch between the parts in a container and the r包eq装uir箱em中en的ts o零f t件he与 lab其el,需 su要ch的 as标:签不匹配,如:nmixed right-and left-hand parts左右件混装ncolored parts不同颜色的零件nmixed part types不同种类的零件混装nwrong part numbers零件号错误PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Label Error ProofingIdentify probable causes of mislabeling识别可能导致贴错标签的原因Understand prevention techniques for probable causes了解针对可能原因的预防方法Identify procedures for labeling the returnable container path明确对于可回用的包装箱贴标签的流程PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
PROBABLE CAUSES OF MISLABELING可能导致贴错标签的原因�Parts Without Labels无标识的零件�Labels Without Parts贴有标签的空包装箱�Informal Changeover随意的更换生产零件�Dependent Labels非独立的标签�Lack Of Error Proofing缺少防错�Lack of Documented Labeling Process /Training / Communication没有与贴标签相关的文件/培训/沟通�Lack Of Workplace Organization缺少车间现场的5S管理PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Common MislabelingOccurrences-Parts w/o Labels常见的贴错标签情况-零件错误�PartialContainers包装箱未装满�Unlabeled/Poorly Labeled Finished Goods制成品无标签或标签不全�Unlabeled/Poorly Labeled Scrap报废品无标签或标签不全�Unlabeled/Poorly Labeled WIP在制品无标签或标签不全�Unidentified Repair无标识的返工件�Repack重新装箱�Engineering Samples工程样品�Parts in the Office Area办公室区域的零件PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common MislabelingOccurrences常见的贴错标签情况To prevent parts without labels...防止无标签的零件…Use bar-coded labels使用条形码标签Know location of parts了解零件的定置管理Eliminate partials when possible尽可能的避免不满箱Build to standard pack建立标准的包装PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common MislabelingOccurrences-Labels w/o Parts 常见的贴错标签情况-标签错误�Old Labels on Returnable Containers 回用包装箱上的旧标签�Pre-printed Labels in “Office”在办公室预先打印好的标签�P在re生-pr产int现ed场 La预bel先s a打t W印or好kst的ati标on签�N对o 预Co先ntr打ol 印of 好Pre的-Pr标int签ed无 La控be制ls�Labels Fall Off Containers标签从包装箱掉落�C预on先ta贴ine好rs 标La签bel的ed 空Ah包ea装d箱11234567890234566543217x89xxxxxxxxx0xZZZZZZZZ12x3x45x67x8x�Qua12345678ZZZZZZZZZ65Z4Z32ZZ1Z事先lit粘y D贴ots合 L格abe品le标d A识headZZZZZZZZZZ6543211234567890xxxxxxxxZZZZZZZZZZZZZZZZ321654901234567834567812ZZZZZxxxxxxxxZZZZZZZZZZZ781234561234567890654321123xxxxxxxx45ZZZZZZZZ67x89x0x2112345678ZZZZZZZZ12x65433x45x67x8xZ65Z4Z312345678902ZZ1ZZZZZZZZZZZZxxxxxxxxZZZZZZZZZZZZZZZ81234567PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common MislabelingOccurrences常见的贴错标签情况To prevent labels without parts...防止无零件的标签…Avoid handwritten labels避免使用手写的标签Remove old labels去掉旧的标签Eliminate label inventory消除存余的标签Print on demand即时打印标签Implement clear process实施清晰的流程PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Common MislabelingOccurrences常见的贴错标签情况To prevent labels without parts...防止无零件的标签…Use independent labels使用独立标签Define accountability定义标签的可靠性Apply label at lead operation根据需要在操作工位打印标签Conduct labeling audit导入标签审核Combine like labels合并相似的标签PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Common MislabelingOccurrences常见的贴错标签情况To prevent problems with...防止以下问题…nReworkE返工ngineering changes工程更改Use designated area使用指定的区域Follow procedure跟踪程序Follow standard rework proceduresCommunicate沟通遵循标准化作业程序Handwritten Labels手写标签Re-verify and inspect all reworkedmaterialE重新确认检查所有返工的材料liminate消除Never reuse old labels不要重复使用旧标签nPartials不满箱Clearly label partial containers “PARTIAL”在未装满的包装箱上明确标识“未满箱”PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Common MislabelingOccurrences-Informal Changeover常见的贴错标签情况-随意更换生产零件�Changeover is Not an Event更换生产产品不是件小事�L缺ac少k o文f D件oc化um的en产ted品 C更ha换nge程ov序er Process�L贴ab标eli签ng没 is 有No包t a含 Pa在rt o产f C品ha更ng换eo程ver序 Pr中ocedure�N对o 未Fo满rce箱d W的a产y to品 R无e-I强ntro制du措ce施 Pa使rti其als返 to回 the生 L产ine线�U无ns计ch划ed的ule进d P行ro产du品ctio更n 换ChangesPDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common MislabelingOccurrences常见的贴错标签情况To prevent problems with changeovers...防止在更换产品时发生的问题…Document procedure建立文件化程序Communicate procedure建立沟通程序Follow up跟踪PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Common Mislabeling Occurrences常见的贴错标签情况Lack of Error Proofing缺少防错First ManufacturingStep生产第一步Last Manufacturing Step生产最后一步Apply Label (Less than 3 seconds)贴标签(3秒内)No Error Detection无错误探测GM Assembly CenterGM装配中心100% Inspection100%全检Detect defect and issue PRR发现缺陷发布PRRPDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common Mislabeling Occurrences常见的贴错标签情况LACK OF DOCUMENTED LABELING PROCESS / TRAINING / COMMUNICATION没有与贴标签相关的文件/培训/沟通�Lacking Sufficient Detail缺少足够的细节�Not Included in Training & Retraining没有包含在培训和再培训程序中�Not Available to Operator at Work Cell工作现场无作业指导文件�Responsibility Undefined职责不明确�Not Included in the PFMEA没有包含在PFMEA中�No Layered Audits to Verify Compliance未在层级审核中验证其执行情况PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Common Mislabeling Occurrences常见的贴错标签情况LACK OF WORKPLACE ORGANIZATION缺少车间现场的5S管理�No Set Place for Things物品无定置管理�Lack of Cleanliness; Clutter现场混乱不清洁�No Sample Boards at Workstation工作区域无样品板�More Tools, Racks, Labels Than Necessary不必要的工具,料架和标签�Too Much Inventory in the Work Cell现场存货过多�Operator Layout is Not Friendly操作工位布局不合理�No “Running Now”Display at Workstation现场无正在生产何种产品的标识PDF 文件使用 "pdfFactory Pro" 试用版本创建 暙ww3w .
Labeling the Returnable Container Path回用包装箱的贴标签步骤Printing the GM Label打印GM标签Applying the Label贴标签Returnable Containers回用包装箱PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw ÿw 1724 A L A B E L S
To prevent mislabeling whenprinting the GM 1724 A label...打印标签时的防错方法…Eliminate manually generated labels取消所有手工填写的标签Print labels on demand根据需要即时打印标签Document procedure建立文件化程序PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw ÿw 1724 A L A B E L S
To prevent mislabeling when applying the GM 1724 A label...贴标签时的防错…Label one container at a time每次贴一个包装箱Label only containers to be shipped标签只能贴在有零件的准备发运的包装箱上Install verification process建立确认程序Establish backup plan建立备用方案Implement training实施培训Include labeling audit in process在过程中增加标签审核PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw ÿw 1724 A L A B E L S
Returnable Containers回用包装箱Removal of old labels撕去旧标签nDocument a plan to remove old labels在文件中规定撕去旧标签nNever remove labels at the production line不要在生产线上撕标签nDesignate areas to remove old labels指定专门区域撕标签nNever reuse old labels不要重新使用旧标签nTear up/destroy old labels销毁旧标签PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Returnable Containers回用包装箱Maintenance of Returnable Containers Prevention Methods:维护回用包装箱时的防错方法:nDesign a tracking system for returnables针对回用包装箱建立跟踪体系nDesign a maintenance program for returnables针对回用包装箱建立维护程序nCommunicate frequently with your GM contact person与你在GM公司的联系人随时保持联系PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Container Ownership包装箱的所有者To ensure that container content is consistent with label information, the supplier is responsible for removing all labels from returned containers.为确保包装箱内的产品与标签信息的一致性,供应商有责任去除回用包装箱上的旧标签PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
KEY CONCEPT关键概念MislabeledPartsSupplierGM Assembly CenterLABEL ERROR标签错误DEFECT缺陷DETECTLABELINGPREVENT ERRORS发现标签错误LABELINGDEFECTS避免标签缺陷PDF 文件使用 "pdfFactory Pro" 试用版本创建 èw
The Process Map过程分析图5 Steps to build the Error Proofing Map :建立防错分析图的5个步骤: a specific area of the process to study确定一个过程进行研究 header cards for each operation为每一个工位建立一个标题卡 problem cards to identify opportunities for errors / defects每个标题下建立问题卡定义可能发生的错误/缺陷 action cards to eliminate errors / defects为排除错误/缺陷建立对应的行动卡 the actions on the actionitem list收集所有行动卡汇总到反应计划清单上PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Brainstorming Questions头脑风暴的问题H在as这 m个isl工abe位lin上g e是ve否r o曾ccu经rre发d 生dur过ing贴 th错is 标ste签p i的n t问he 题process??I在s i这t po个ss工ibl位e f上or a是 m否isl可abe能l t发o o生cc贴ur d错ur标ing签 th的is 问ste题p in the process??I在s i这t pr个ob工ab位le t上ha发t m生isla贴be错lin标g w签ill的 oc可cur能 in性 th有is s多tep少 of the process??W找h出ich哪 of些 th问e o题pp是ort首un要itie需s a要re 解the决 m的ost important to address??W我h们at 能can做 w些e d什o t么o e，lim要ina想te在 the这 o个ppo工rtu位ni上ty f不or 出mi现sla贴bel错ing标 in签 th的is s可te能p o性f the process?,?PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Ideas for Improvement改进的意见Methods方法Devices设施Procedures程序PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍－－Introductions相互介绍－－Why Are We Here？我们的活动目的。－－Problems description 问题描述vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术－－DFM （可制造性设计）－－Poka－Yoke （防错）vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Error Proofing MapOperation Operation Operation Operation Operation Operation 123456What is it?A picture of causes for errors and actions to eliminate 文件使用 "pdfFactory Pro" 试用版本创建 ÿw Øw
Error Proofing Map5 Steps to build the Error Proofing Map : a specific area of the process to header cards for each problem cards to identify opportunities for errors / action cards to eliminate errors / the actions on the action item listPDF 文件使用 "pdfFactory Pro" 试用版本创建 Øw
Error Proofing MapOperation Operation Operation Operation Operation Operation 123456Header CardsEach header card describes a major operation in the CardsProblem cards reveal a potential error/defectAction CardsSignify improvements that the team has agreed to implement, which will be written on an action item 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing MapOperation Operation Operation Operation Operation Operation 123456Header CardsEach header card describes a major operation in the CardsProblem cards reveal a potential error/defectAction CardsSignify improvements that the team has agreed to implement, which will be written on an action item 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Error Proofing MapOperation Operation Operation Operation Operation Operation 123456Header CardsEach header card describes a major operation in the CardsProblem cards reveal a potential error/defectAction CardsSignify improvements that the team has agreed to implement, which will be written on an action item 文件使用 "pdfFactory Pro" 试用版本创建 ÿw Øw
Error Proofing MapAction ItemsPDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
ERROR PROOFING TECHNIQUESWORKSHOP AGENDA防错技术研讨会议程vOPENING COMMENTS & INTRODUCTIONS开场白及互相介绍vERROR PROOFING OVERVIEW防错技术概论vERROR PROOFINGTECHNIQUES防错技术vLabel Error－Proofing标签防错vBRAINSTORMING ----Problem Solving Solutions Utilizing Error Proofing Techniques头脑风暴----解决问题的方案应用防错技术vDEVELOP ACTION PLANS & IMPLEMENTATION制定行动计划并实施vCLOSING & WRAP-UP总结并结束PDF 文件使用 "pdfFactory Pro" 试用版本创建 ±ww ÿw .
Parking Brake -------Before倒车闸－－之前•In this example the threaded fastener used to secure the parkingbrake is not always properly secured. 本例子中，用于紧固倒车闸的螺纹紧固螺栓常常没有正确紧固。•This error is causing many warranty claims.这种错误常常导致较多的售后抱怨。倒车闸×倒车手闸可能没有正确紧固。×上述情况很难探测到。Prior to proceeding to the next page, think about how you might change this design to prevent this error from occurring.在揭晓答案之前，想想你如何能通过设计来预防这类错误的发生。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
•Parking Brake -After•刹车闸－－之后刹车手闸×新设计采用卡扣式，无需任何紧固件。－－Would this snap-fit design be desirable if the Parking Brake Handle was an item that would need to be serviced regularly? －－如果刹车闸可能是常见的售后服务件，这种卡扣式设计是否理想？－－No –because the snap-fit would be difficult to remove. Remember that in this course we are focusing on error proofing. Back at your desk you will have to factor in all of the requirements.－－显然不是－－因为这种设计难于拆卸。但是本课程我们针对的是防错。所以我们还必须考虑所有要求。PDF 文件使用 "pdfFactory Pro" 试用版本创建
•Cassette Deck Labels –Before•盒式音响面板标识条－－－之前•In this example, the symmetric shape of the Cassette Deck Labelsallows the label to be installed two ways –only one is the correct way!本例子中，对称的标识条可以不同方向装配，但只有一个方向是正确的。盒式音响面板标识：旧设计－容易倒装PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
•Cassette Deck Labels –After•盒式音响面板标识条－－－之后盒式音响面板标识条新设计－－都能正确安装If there is only one correct way to install a part, that part should be designed so that it can only be installed the one, correct way.如果这个标识条只能有一种方式安装，那就能正确安装了。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Battery Installation –Before蓄电池安装－－－之前－－As batteries were being taken off of loading racks by an assist device, and then installed into the engine compartment, some of the batteries were being oriented incorrectly. 辅助设备把蓄电池从产品箱中取出，然后就安装到发动机仓内，有时蓄电池方向错误蓄电池安装×蓄电池可能被机器手装错方向－－Before proceeding to the next page, think about how you might attempt to error proof this situation.翻开下页之前，想想如何对这种情况实施防错。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
Battery Installation –After蓄电池安装－－－之后－－Note that we could have done a lot of real fancy robotic programming or process controls in order to error proof this situation. Howevera simple tab on the loading rack does the trick. This was an inexpensive, simple wayto resolve this problem.注意到我们为了防错，可能会在机器人实时模糊编程或工艺控制中花大力气加以控制，然而其实只要在上料架上采用一块挡板就可以达到目的，这是一种简便易行的方法，－－The KISS principle –Keep It Simple Stupid –holds true in error proofing. The simplest solution that works is often the best one to use!KISS法则－－让事情变得简单化，傻瓜化。这在防错理论上也是一样的，最简单易行的方案往往是最佳方法。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
•Radiator Hoses –Before散热器软管－－之前•There are many potential errors that can occur during the installation of radiator hoses.•散热器软管安装时很容易发生许多不易察觉的错误。散热器软管三种潜在失效模式－－1）装错软管类型2）软管方向装错3）软管没有紧固到位上述缺陷难于探测到。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
•Radiator Hoses –After散热器软管－－之后•By putting visual controls right on the radiator hoses, the operator is aided during installation. •在软管上设置位置控制标识条，这样操作工在安装时就有章可循。软管控制标识OPIS（操作工/产品识别系统）在很多地方能够解决一些错误模式。1）标识“上”“下”“左”“右”等2）和连接的歧管漆成同样颜色标识3）颜色漆带帮助辨别软管方向4）卡箍卡在颜色带之内。PDF 文件使用 "pdfFactory Pro" 试用版本创建 ÿw
