防誤措施
MISTAKE-PROOFING 防誤措施
ACE Elements

ACE 內(nèi)容
ACE Elements
ACE 內(nèi)容
Benefits of Mistake-Proofing 防誤措施的好處
Increase profitability by eliminating inadvertent mistakes
消除無(wú)謂的錯(cuò)誤可增加利潤(rùn)率

Increase productivity by reducing wasted time
減少浪費(fèi)的時(shí)間可提高生產(chǎn)力

Improve customer satisfaction and quality by eliminating escapes
消除逃脫可提高客戶滿意度和質(zhì)量

Increase reliability by continuously improving products, services or processes
不斷改進(jìn)產(chǎn)品、服務(wù)或程序可提高信譽(yù)
Mistakes vs. Defects 錯(cuò)誤vs 過(guò)失
They are not the same thing! Mistakes Cause Defects.
他們是不同的！ 錯(cuò)誤導(dǎo)致過(guò)失
Most Common Mistakes 最常見的錯(cuò)誤
Misunderstanding requirements
誤解了要求

Skipping a process step or tasks
漏掉了一個(gè)工作步驟

Performing process steps incorrectly or in the wrong order
未正確地或以錯(cuò)誤地順序執(zhí)行程序步驟

Contamination
污染
Leaving out a part or a piece of information
漏掉了一個(gè)零件或一條信息

Adjustment and measurement mistakes
調(diào)節(jié)和測(cè)量錯(cuò)誤

Timing mistakes
定時(shí)錯(cuò)誤

Using the wrong part, tool or information
使用了錯(cuò)誤的零件、工具或信息
Mistake-Proofing 防誤措施
Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly.
防誤措施是指運(yùn)用智慧和獨(dú)創(chuàng)性發(fā)展出一個(gè)能確保任務(wù)總是能正確完成的設(shè)備的方法。


It removes uncertainty from the situations where errors are most likely to occur, such as:
它去除了最可能發(fā)生錯(cuò)誤的情形中的不確定性，如：
Repetitive tasks 重復(fù)性的任務(wù)
Complex instructions 復(fù)雜的說(shuō)明書
Calculations / Adjustments 計(jì)算/調(diào)節(jié)
Look-alike parts 相似的零件

Why do we do Mistake Proofing? 為什么我們要采用防誤措施？
To prevent turnbacks and customer escapes from recurring, since the cost to fix a problem increases rapidly the later it is found:
為防止缺陷和客戶逃脫情況再次發(fā)生，因?yàn)閱?wèn)題發(fā)現(xiàn)得越晚所花的費(fèi)用就會(huì)迅速增加：
2 Approaches to Mistake Proofing 預(yù)防錯(cuò)誤的2個(gè)途徑
Mistake-Proof 防誤措施
the Design 設(shè)計(jì)

Redesign the product
重新設(shè)計(jì)產(chǎn)品
Eliminate the mistake condition
消除犯錯(cuò)誤的條件
Redesign for symmetry or asymmetry
重新進(jìn)行對(duì)稱或不對(duì)稱設(shè)計(jì)
Change the materials
改變材料
Change component type, characteristics or supplier
改變組件的類型、特征或供應(yīng)商
Mistake-Proof 防誤措施
the Process 加工

Change or add tooling
改變或增添工具

Change process steps
改變加工步驟

Add use of checklists, templates or gages
增加使用清單、模板或測(cè)量?jī)x

Implement control charts
執(zhí)行控制圖表

Example of Mistake-Proofing the Design 防誤措施范例 設(shè)計(jì)
Process Description: Making a pot of coffee
程序描述：泡一壺咖啡
Example of Mistake-Proofing the Design 防誤措施范例 設(shè)計(jì)
Process Description: Making a pot of coffee
程序描述：泡一壺咖啡
Example of Mistake-Proofing the Design 防誤措施范例 設(shè)計(jì)
Process Description: A label is pasted into a recess in a molded chassis
程序描述：將標(biāo)簽貼在底盤的凹槽內(nèi)
Example of Mistake-Proofing the Design 防誤措施范例 設(shè)計(jì)
Process Description: Install slides into a slide projector
程序描述：將幻燈片裝入幻燈機(jī)中
Example of Mistake-Proofing the Design 防誤措施范例 設(shè)計(jì)
Process Description: Torquing a number of bolts recessed deep in a cavity.
程序描述：將大量螺栓擰進(jìn)空腔深處的凹槽內(nèi)
Mistake-Proofing isn’t Words! 防誤措施不是文字！
Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly.
防誤措施是指運(yùn)用智慧和獨(dú)創(chuàng)性發(fā)展出一個(gè)能確保任務(wù)總是能正確完成的設(shè)備的方法。
Most Common Types of Mistake-Proof Devices 最常見的防誤設(shè)備
Guide pins or interference pins
向?qū)D釘或干涉圖釘

Templates
模板

Part kits using shadowboxing
使用能防止錯(cuò)誤的零件包

Limit switches
限制閥

Counters
計(jì)算器

Alarms
鬧鐘

Weights and measures
稱重秤和測(cè)量?jī)x

Checklists
清單

Control charts
控制圖表
Mistake-Proofing Process Changes 防誤碼程序的改變

Improve the process! 改進(jìn)程序！
Simplify 簡(jiǎn)單化
Reduce steps, parts, forms, data on forms, number of process steps, etc.
減少步驟、零件、表格、表格上的數(shù)據(jù)、加工步驟的數(shù)量等。
Consolidate/Co-Locate 鞏固/共用
Bring operations closer together, reduce work-in-process (WIP)
使操作變得更緊湊，減少過(guò)程工作（WIP）
Standardize 標(biāo)準(zhǔn)化
Make the process visual 使程序可見
Move responsibility and authority down in the organization
將責(zé)任和權(quán)利下放給組織
Creating Mistake Proofing 創(chuàng)建防誤措施
Try-Storming (vs. Brainstorming)
嘗試風(fēng)暴 （對(duì)頭腦風(fēng)暴）

Involve the right people
讓合適的人參與

Walk the process and get the facts
檢驗(yàn)程序并獲得事實(shí)

Don’t just sit and think about solutions... TRY THEM!
不要只是坐在那兒想解決問(wèn)題的方法…
去嘗試！
Test Mistake Proofing with the “Nasty Test” 用“惡心的試驗(yàn)”來(lái)驗(yàn)證防誤措施
The “Nasty Test” (vs. the “Solution”)
“惡心的試驗(yàn)” （對(duì)“解決方法”）
When you think you’ve got the best solution… TRY TO MAKE IT FAIL!!!
當(dāng)你認(rèn)為你已找到最佳解決方法時(shí)… 試著去讓它失敗
Involve all users
讓所有使用者參與
Mistake-proof devices must be 100% effective at dealing with a particular mistake
在處理特殊錯(cuò)誤時(shí)防誤設(shè)備必須100%有效
If not, they will be ignored
如果不能，就應(yīng)放棄
Ensure the mistake-proof doesn’t create another problem
確保防誤措施不會(huì)引起其它問(wèn)題
When do you do Mistake-Proofing 何時(shí)采取防誤措施
Formally, as part of the QCPC/MFA Process
形式上的，作為QCPC/MFA程序中一部分
Three Levels of Mistake-Proofing 防誤措施的三個(gè)等級(jí)
There are 3 Levels of Mistake-Proofing based on effectiveness and speed:
防誤措施有三個(gè)基于有效性和速度的等級(jí)：
Level III: Detection
等級(jí)三：發(fā)現(xiàn)

Level II: Alert
等級(jí)二：警告

Level I: Prevention
等級(jí)一：防止
Three Levels of Mistake-Proofing 防誤措施的三個(gè)等級(jí)
Level III, Detect: Allows you to detect your Mistake after it has occurred. (1 point)
等級(jí)三，發(fā)現(xiàn)：在已經(jīng)發(fā)生之后發(fā)現(xiàn)錯(cuò)誤
Checklists 清單
Computer beeps 電腦提醒
Manually activated Spell Check 手工拼寫檢查
Level II, Alert: Alerts you as the Mistake is happening. (2 points)
等級(jí)二，警告：當(dāng)錯(cuò)誤正在發(fā)生時(shí)提醒你
Sensors, alarms, control charts 傳感器、鬧鐘、控制圖表
Counters 計(jì)算器
Automatic Spell Check 自動(dòng)拼寫檢查
Level I, Prevent: Prevents you from making the Mistake. (3 points)
等級(jí)三，防止：防止你犯錯(cuò)誤
Eliminating the mistake condition (changing the design)
消除犯錯(cuò)條件
Automation 自動(dòng)控制
Spelling “Auto-corrector” 拼寫“自動(dòng)更正器”
Mistake Proofing Qualifying Level Items 防誤措施合格水平內(nèi)容
The following 2 items are required to achieve the ACE Qualifying level for Mistake Proofing
要取得ACE的防誤措施合格資格必須完成以下兩項(xiàng)內(nèi)容
Summary 總結(jié)
Mistakes are not inevitable.
錯(cuò)誤不是不可避免的。
A Mistake-Proof is a creative device that prevents a mistake from happening. It should be:
防誤措施是一項(xiàng)有創(chuàng)造性的設(shè)備能防止錯(cuò)誤發(fā)生。它應(yīng)該是：
Simple 簡(jiǎn)單的
Inexpensive 不昂貴的
Reliable at preventing defects or giving prompt feedback.
在防止錯(cuò)誤或給出提示反饋時(shí)可靠的。
Mistake Proofing is critical to process improvement.
防誤措施對(duì)程序改進(jìn)很重要。
Necessary to achieve QCPC turnback reduction goals.
對(duì)達(dá)到QCPC減少缺陷的目標(biāo)是必要的
Mistake-Proofing enhances our work environment by making it easier to do our jobs well.
防誤措施通過(guò)使我們的工作更容易作好來(lái)改善我們的工作環(huán)境

防誤措施