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1、A Strategy for Performance Excellence1Executive OverviewParticipant manualTools WorkbookKnowledge BreakthroughLecture notesLecture notesPerformance Excellence SeriesTraining Module Elements2Table of ContentsPoka-Yoke Mistake ProofingSession 1.0Introduction.3Session 2.0Zero Defects&Costs.7Session 3.0
2、Waste Management.12Session 4.0Zero Defect QualityZDQ.19Session 5.0Understanding Process Errors.27Session 6.0Four Elements of ZDQ.35Session 7.0Seven Steps to Poka-Yoke.42Session 8.0Poka-Yoke Methods.44Session 9.0Summary.673IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding
3、Process ErrorsFour Elements of ZDQSeven Steps To Poka-Yoke AttainmentPoka-Yoke MethodsSummary4Why is“Zero Defects an Important Concept?Key Element in our capability to implement Kaizen-Lean Manufacturing Systems.No need for“just in case inventoriesAllows pany to make only what the customer needs.5Wh
4、y KaizenTimeCPI ProjectTimeCPITimeSavingsSavingsSavingsProcess Improvement Project ImplementedMaintenance of Process PerformanceKaizen6 Sigma Data Driven Methodology to Magnify Impact of Process Improvement Apply Control Techniques to Eliminate Erosion of Improvements Proceduralize/Standardize Impro
5、vements for Improved Maintenance of Critical Process ParametersKaizen Use Small Teams to Optimize Process Performance by Implementing Incremental Change Apply Intellectual Capital of Team Members Intimate with Process CPI Projects Emphasize Control and Long Term MaintenanceKaizen Projects Emphasize
6、Incremental Improvements6MajorCPITools6s s Kaizen LeanDescriptionCp/Cpk 44Process capability assessmentDOE 44Design of experimentsSPC 44Process control based on statistics and data analysisFMEA 44Risk assessment toolRegression 44Correlate effect one variable has on anotherProcess Map 44 44 44Map pro
7、cess steps to municate and identify opportunities5 whys/2 hows 4 4 4 4 4 4 Determination methods for root cause discoveryPareto 44 44 44Column chart ranking items highest to lowestFishbone 44 4 4 44Cause/Effect Diagram5S 44 44Elimination wasteVisual Mgmt 44 4 4 44Emphasis on visual techniques to man
8、age processPoka-Yoke 4 4 44Error proofing techniquesSpaghetti Chart 44 44Kanban 4 4 44Material storage technique used to control processTakt Time 44 44Determine pace or beat of a processStd Work 44 44Evaluate tasks done during a processSMED 44 44Single minute exchange of dies-Quick machine set upTPM
9、 44 44Integrate maintenance strategy with processCellular Flow 44 44Reduce inventory&cycle time through process layout and pull production techniquesExpand Process Improvement Program to Utilize Kaizen Tool Kit Tool Kit parison7IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUndersta
10、nding Process ErrorsFour Elements of ZDQSeven Steps to Poka-Yoke AttainmentPoka-Yoke MethodsSummary8Why is“Zero Defects an Important Concept?Maintain Customer Satisfaction&LoyaltyHappy Customers mean more sales!9Why is“Zero Defects an Important Concept?COSTThere is always a cost associated with manu
11、facturing defects!10Costs of Defects?Does it cost more to make processes better?NOMaking processes better leads to reducedReworkScrapWarranty costsInspection costs111-10-100 RuleThe 1-10-100 rule states that as a product or service moves through the production system,the cost of correcting An error
12、multiplies by 10.ActivityCost Order entered correctly$1Error detected in billing$10Error detected by customer$100Dissatisfied customer shares the experience with others the costs is$100012IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQ
13、Seven Steps to Poka-Yoke AttainmentPoka-Yoke MethodsSummary13Why is“Zero Defects an Important Concept?Key Element in our capability to eliminate waste.DefectsMisused resourcesInventoriesUntapped ResourcesMotionsDelaysProcesses14What is Waste?Everything we do that costs something without adding value
14、 to the productOur objective Value added=MaximumNon-Value Added=Minimum15The nine types of wasteOverproductionDelays waiting timeTransportationProcessInventoriesMotionsDefective productsUntapped resourcesMisused resources 9 Wastes16Continuous ImprovementIs the continuous elimination of waste17Elimin
15、ation of WasteThe MethodCheck and measure resultsIdentify wasteSearch for causesImplement continuous improvement18Elimination of Wastes and Continuous ImprovementnElimination of wastesnKAIZENnContinuous ImprovementnOne piece flownSMEDnVisual ControlsnWorkplace OrganizationnKanbannStandard WorknProce
16、ss ControlnTotal Productive MaintenancenPoka-YokeLeadtimeCostsQuality the First TimeThe ApproachThe MeansThe Strategy19IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQSeven Steps to Poka-Yoke AttainmentPoka-Yoke MethodsSummary20What is
17、a Zero Defect Quality System ZDQ?A quality concept to manufacture ZERO defects&elimination of waste associated with defects!“ZERO is the goal!21What is a Zero Defect Quality System ZDQ?Based on a discipline that defects are prevented.Control the process so that defects are impossible!22What is a Zer
18、o Defect Quality System ZDQ?No Finger Pointing.Operators and Machines will sometimes make mistakes.Find ways to keep errors from be ing defects!23What is a Zero Defect Quality System ZDQ?A Method for Mistake-Proofing Poka-yoke a process.ZDQ assures that defects are not shipped!24How ZDQ Makes Work E
19、asierMistake-Proof or Poka-yoke the process!Recognize that it is natural for people to make mistakes.25How ZDQ Makes Work EasierMistake-Proof or Poka-yoke the process!Not noticing that an error is made or a machine is not functioning does not make a person stupid or foolish.26How Do We Achieve ZDQ?M
20、istake-Proof or Poka-yoke the process!Errors never be e defects!No finger pointing after the fact.No mandate to do better next time.27IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQSeven Steps to Poka-Yoke AttainmentPoka-Yoke MethodsSu
21、mmary28Poka-Yoke results in Quality of Processes Dedicated linesOne piece flowTransformation=Quality production the 1st time Inspection.eliminated?TransportStorageDelay/waitLeadtimeQuality the 1st time Cost29Relationship between processes and quality defects.Almost any business activity can be consi
22、dered a process.Production processes involve the flow of material.Machining,assembly,and packaging are typical production processes.Business processes involve the flow of information.Financial planning,purchasing&order entry are typical business processes.All processes have the potential for defects
23、.Hence,all processes offer a opportunity for the elimination of defects and the resultant quality improvement.30In order to reduce quality defects and stop throwing away money,we must Understand the process an its relationship to other business processes.Identify the inputs and outputs of the proces
24、s.Know who are the suppliers to and customers of the process.=Reduce the variation of the processAnd31What Causes Defects?Process Variation From1.Poor procedures or standards.2.Machines.3.Non-conforming material.4.Worn tooling.5.Human Mistakes.Except for human mistakes these conditions can be predic
25、ted and corrective action can be implemented to eliminate the cause of defects32What Causes Defects?Human MistakesSimple errors-the most mon cause of defects-occur unpredictably.The goal of ZDQ is zero!Make certain that the required conditions are in place and controlled to make acceptable product 1
26、00%of the time.33Ten Types of Human MistakesForgetfulnessMisunderstandingWrong identificationLack of experienceWillful ignoring rules or procedureInadvertent or sloppinessSlowlinessLack of standardizationSurprise unexpected machine operation,etc.Intentional sabotage3435IntroductionDefects&CostsWaste
27、 ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQSeven Steps to Poka-Yoke AttainmentPoka-Yoke MethodsSummary36The 4 ponents of ZDQZDQ functions by bining four elementary ponents:1.Point of Origin Inspection2.100%Audit Checks3.Immediate Feedback4.Poka-Yoke37Inspection
28、The 3 basic approaches to inspection of processed product are:Judgement/Standard InspectionInformative InspectionPoint of Origin InspectionThe first two approaches are widely used and considered traditional.Only Point of Origin Inspection actually eliminates defects.38Point of Origin InspectionFocus
29、 on prevention,not detection.One of the 4 basic elements of ZDQ.Differs from Judgement and Informative:Catches errorsGives feedback before processingNo risk of making more defective productDetect ErrorFeedback/Corrective ActionProcess with Zero DefectsBy bining Check and Do in the ZDQ approach;the D
30、oing is controlled so it cannot be wrong 100%of the time!May include:Switches that detect miss-fed parts Pins that prevent miss-feeding Warning lights Sound signals39ZDQ/Check and Do/Point of Origin InspectionPoint of Origin InspectionCheck for optimum process conditions before processing is done an
31、d errors can be made.Instant feedback.Corrections made before defects occur.40100%Audit ChecksPoint of Origin Inspection on every piece.The second of the 4 basic elements of ZDQ.Differs from SQC inspection:Does not rely on samplingPrevents defectsDoes not assume defects will statistically occur100%A
32、udit checks everything on the line!Zero Defects41Quick FeedbackError correction as soon as possibleThe third of the 4 basic elements of ZDQ.Differs from traditional inspection approaches that:Correct problems after the processAddress the problem when errors are already defectsIn some cases never ide
33、ntify an error has occurredZDQ sends the operator a signal and alarms the person that an error has happened!ZDQ Inspections=Immediate Feedback42IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQSeven Steps to Poka-Yoke AttainmentPoka-Yoke
34、 MethodsSummary43The Seven Guidelines to Poka-Yoke Attainment1.Quality Processes-Design“Robust quality processes to achieve zero defects.2.Utilize a Team Environment-leverage the teams knowledge,experience to enhance the improvement efforts.3.Elimination of Errors-Utilize a robust problem solving me
35、thodology to drive defects towards zero.4.Eliminate the“Root Cause of The Errors-Use the 5 Whys and 2 Hs approach 5.Do It Right The First Time-Utilizing resources to perform functions correctly the“first time.6.Eliminate Non-Value Added Decisions-Dont make excuses-just do it!7.Implement an Increment
36、al Continual Improvement Approach-implement improvement actions immediately and focus on incremental improvements;efforts do not have to result in a 100%improvement immediately.44IntroductionDefects&CostsWaste ManagementZero Defect Quality ZDQUnderstanding Process ErrorsFour Elements of ZDQSeven Ste
37、ps to Poka-Yoke AttainmentPoka-Yoke MethodsSummary45Poka-yokeMistake-proofing systemsThe fourth of the 4 basic elements of ZDQ.Does not rely on operators catching mistakesInexpensive Point of Origin inspectionQuick feedback 100%of the time“The machine shut down.We must have made an error!BEEP!BEEP!B
38、EEP!Most Poka-yoke devices are sensor or jig devices that assure 100%pliance all the time!46Poka-yokeWhat is Poke-yoke?A method that uses sensor or other devices for catching errors that may pass by operators or assemblers.Poka-yoke effects two key elements of ZDQ:Identifying the defect immediately
39、Point of Origin InspectionQuick Feedback for Corrective ActionHow effective the system is depends on where it is used:Point of Origin or How effective the system is depends on where it is used:Point of Origin or Informative Inspection.Informative Inspection.Poka-yoke detects an error,gives a warning
40、,and can shuts down the process.47Poka-yokePoke-yoke and Point of Origin Inspections Proactive Approach:A fully implemented ZDQ system requires Poka-yoke usage at or before the inspection points during the process.Poka-yoke will catch the errors before a defective part is manufactured 100%of the tim
41、e.48Poka-yokePoka-yoke and Informative Inspection Reactive Approach:Check occurs immediately after the process.Can be an operator check at the process or successive check at the next process.Not 100%effective,will not eliminate all defects.Effective in preventing defects from being passed to next pr
42、ocess.Although not as effective as the Source inspection approach,this methodology is more effective than statistical sampling and does provide feedback in reducing defects.49Poka-yoke Systems Govern the ProcessTwo Poka-Yoke System approaches are utilized in manufacturing which lead to successful ZD
43、Q:1.Control ApproachShuts down the process when an error occurs.Keeps the“suspect part in place when an operation is in plete.2.Warning ApproachSignals the operator to stop the process and correct the problem.50Control SystemTakes human element out of the equation;does not depend on an operator or a
44、ssembler.Has a high capability of achieving zero defects.Machine stops when an irregularity is detected.“There must have been an error detected;the machine shut down by itself!51Warning SystemSometimes an automatic shut off system is not an option.A warning or alarm system can be used to get an oper
45、ators attention.Below left is an example of an alarm system using dials,lights and sounds to bring attention to the problem.Color coding is also an effective non automatic option.BEEP!BEEP!BEEP!“Im glad the alarm went off,now Im not making defects!52Methods for Using Poka-yokePoka-yoke systems consi
46、st of three primary methods:1.Contact2.Counting3.Motion-SequenceEach method can be used in a control system or a warning system.Each method uses a different process prevention approach for dealing with irregularities.53Contact MethodA contact method functions by detecting whether a sensing device ma
47、kes contact with a part or object within the process.Missing cylinder;piston fully extended alarm soundsContact Method using limit switches identifies missing cylinder.An example of a physical contact method is limit switches that are pressed when cylinders are driven into a piston.The switches are
48、connected to pistons that hold the part in place.In this example,a cylinder is missing and the part is not released to the next process.Cannot proceed to next step.Cylinder present54Physical Contact DevicesLimit SwitchesToggle Switches55Energy Contact DevicesPhotoelectric switches can be used with o
49、bjects that are translucent or transparent depending upon the need.Transmission method:two units,one to transmit light,the other to receive.Reflecting method:PE sensor responds to light reflected from object to detect presence.LightTransmitterReceiverObjectIf object breaks the transmission,the machi
50、ne is signaled to shut down.56Contact DeviceAn example of a contact device using a limit switch.In this case the switch makes contact with a metal barb sensing its presence.If no contact is made the process will shut down.57Contact MethodsDo not have to be high tech!Passive devices are sometimes the