error proofing 1 8/18/00 plant, machine, office layout people supportive practice total productive...
TRANSCRIPT
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Error Proofing
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PLANT,MACHINE,
OFFICELAYOUT
PEOPLESUPPORTIVE
PRACTICE
TOTAL PRODUCTIVEMAINTENANCE
CONTAINER -IZATION/TRANSPOR- TATION
SUPPLIERDEVELOPMENT
LEVELING/SMALL LOT
LEAD TIMEREDUCTION
WPO & VISUALMANAGEMENT
PROCESSCAPABILITY SIX SIGMA
20 KEYS
ErrorProofing Error
EMPLOEEINVOLVEMENT/ WHITE SHIRT
PullSystem
QuickSet-up
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Error Proofing
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To understand the principles ofERROR PROOFING, the reasoning
behind it, and the processes of developing Error Proofing (poka-yoke) devices
GoalsGoals
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Improve quality (reduce PPM & scrap)
Make the processes easier and more capable
Analyze cell for possible Error Proofing
opportunities
Develop Error Proofing devices and ideas
ObjectivesObjectives
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Error Proofing
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The process of anticipating, preventing, & detecting errors which adversely affect customers & result
in waste
Error Proofing IsError Proofing Is
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Error Proofing
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Will Error Proofing be more work to complicate our jobs even further?
How does Error Proofing fit in the AMPS program?
QuestionsQuestions
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Error Proofing
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Error Proofing will make your job easierand safer!
AnswerAnswer
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Error Proofing
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How can the Error Proofing class be used?How can the Error Proofing class be used?
Catalyst for improvementTool for reaching measurablesLearning device
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Error Proofing
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What Measurables does Error Proofing affect?What Measurables does Error Proofing affect?
PPMScrapProcess Capability
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Other BenefitsOther Benefits
Safety ImprovementsQuality ImprovementsErgonomic BenefitsPromotes Design for Manufacturing
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Error Proofing
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Therefore…
Error Proofing Classes only help us reach our measurables for the overall goals established in our 20 Keys.
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Error Proofing
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Error ProofingError Proofing
Think – Quality
Think – Right First Time
Think – Zero Defects
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Maintain customer satisfaction
Reduce cost
Ability to maintain Continuous
Improvement production
methods and smaller inventories
Why Error Proofing?Why Error Proofing?
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Error Proofing
13
SafetyQuality
–Scrap–PPM–Repairs
Why Error Proofing?Why Error Proofing?
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Error Proofing
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Light curtains
Safety ExamplesSafety Examples
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Light curtains
Safety ExamplesSafety Examples
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Error Proofing
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Palm buttons
Safety ExamplesSafety Examples
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Error Proofing
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If it takes 1 hour to fix a problem where
it occurs, it may take 100 hours
downstream, and it may take 1000 hours
at the customer
What are cost implications?
1-100-1000 Rule1-100-1000 Rule
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World Class Benchmarks• PPM 25 or less• Scrap Less than 2%• Suggestions per employee 15 per year• % of suggestions implemented 85%• % of employees on teams 100%• WIP hours Less than 4 hrs.• Employees Cross Trained 100%• Supplier Days Inventory Less than 4 days
Error Proofing Directly AffectsError Proofing Directly Affects
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Error Proofing
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• PPM of 25
22,000 credit cards will have incorrect cardholder information on the magnetic strips.
55,000 pieces of mail mishandled each month.
18 unsafe plane landings at O’Hare each year.
Parts Per MillionParts Per Million
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Error Proofing
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• PPM of 25
$19,000 spent annually on CD’s and tapes that don’t play.
4,000 checks deducted from the wrong bank accounts each day
50,000 documents lost by the IRS each year
Parts Per MillionParts Per Million
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If 75,000 Total shocks and struts go out the door per day, then only 1.875 can be defective to meet the goal of 25 PPM
When the customer gets that defective shock or strut, do they care that the other 74,998 were good?
Parts Per MillionParts Per Million
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If 1000 exhaust systems are produced per shift. How many defects can we have and still be at 25 PPM or less? .025
When the customer gets that defective part or assembly, do they care that the other 999 were good?
Parts Per MillionParts Per Million
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Zero defectsZero wasteZero delays
3 Zeros3 Zeros
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Error Proofing
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• Error Proofing
1. Simple and inexpensive
2. Automatic, or part of process
3. Placed close to mistake, minimizing damage
Error ProofingError Proofing
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Error Proofing
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What are some everyday examples?
Error ProofingError Proofing
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Error Proofing
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Cannot start the car without it being in park
ExamplesExamples
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Error Proofing
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Dryer stops when you open the door
ExamplesExamples
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Error Proofing
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Mower stops when you release the handle
ExamplesExamples
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Inside the Refrigerator
Light goes out when you shut the door
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List examples of error proofing in room
Exercise 1Exercise 1
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Exercise 1
List Error Proofing Devices in the Room
Error Proofing is the process of anticipating, preventing, and detecting errors whichadversely affect customers and result in waste.
1. ______________________________
2. ______________________________
3. ______________________________
4. ______________________________
5. ______________________________
6. ______________________________
7. ______________________________
8. ______________________________
9. ______________________________
10. ______________________________
11. ______________________________
12. ______________________________
13. ______________________________
14. ______________________________
15. ______________________________
16. ______________________________
17. ______________________________
18. ______________________________
19. ______________________________
20. ______________________________
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Error Proofing Devices and Defects
Module 2Module 2
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Uses techniques that prevent errors by:
– Designing processes and products that cannot be
incorrectly performed, manufactured, or assembled
– Using devices or inspection techniques that detect errors
during the work process rather than at the end of the
process
Error ProofingError Proofing
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Simple and inexpensive devices that are used to
prevent errors about to occur or detect errors
and defects that have occurred.
Error Proofing DevicesError Proofing Devices
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Errors and DefectsErrors and Defects
An example of an ERROR would be:
–Loading a part incorrectly in a fixture
A DEFECT would be:
– if that machine were cycled and a bad
part produced
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Error Proofing
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Five Manufacturing examples– Guide pins– Error detection and alarms– Limit switches– Counters– Checklists
Error ProofingError Proofing
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Guide pins allow only the correct baffle to be loaded in the press
ExamplesExamples
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Error Proofing
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Guide pins are used to check alignment of the flange.
ExamplesExamples
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Assembly/Mounting Error
ExamplesExamples
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Limit Switch
ExamplesExamples
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Processing omissions– Leaving out one or more process steps.
Processing errors– Process operations not performed according to the
standard work procedures.Error in setting up the work-piece
– Using the wrong tooling or setting machine adjustments incorrectly for the current product
Ten Causes of ErrorsTen Causes of Errors
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Missing parts– Not all parts included in the assembly, welding, or
other processesImproper part/item
– Wrong part installed in assemblyProcessing wrong work piece
– Wrong part machined
Ten Causes of ErrorsTen Causes of Errors
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Operations errors– Carrying out an operation incorrectly; having the
incorrect revision of a standard process or specification
Adjustment, measurement, dimension errors– Errors in machine adjustments, testing measurements
or dimensions of parts and gages
Ten Causes of ErrorsTen Causes of Errors
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Errors in equipment maintenance or repair– Defects caused by incorrect repairs or component
replacementErrors in preparation of blades, jigs, or tools
– Damaged blades, poorly designed jigs, or wrong tools
Ten Causes of ErrorsTen Causes of Errors
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New worker– Not familiar with operation
Forgetfulness– Lack of concentration and standards from one part to the next
Willful errors– Operator thinks his/her way of doing things is best
Lack of standards– No standardization of work implemented
Surprise errors - equipment– Equipment failures or wrong setup
Five Causes of Human ErrorsFive Causes of Human Errors
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Error takes place
A defect occurs as a result
This information is fed back
Corrective action is taken
accordingly
Traditional Management CycleTraditional Management Cycle
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100% Inspection
SPC
SPC
Traditional AlternativesTraditional Alternatives
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• 100% Inspection
-Costly
-Non-Value Added
-Not fail-safe
Error ProofingError Proofing
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Good Part
Are These Acceptable?
SPCSPC
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• 99.9% Good
20,000 incorrect drug prescriptions will be written in next 12 months
12 babies will be given to the wrong parents every day
291 pacemaker operations will be performed incorrectly this year
Error ProofingError Proofing
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Error Proofing
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• 99.9% Good
811,000 faulty rolls of 35mm film will be loaded this year
268,500 defective tires will be shipped this year
Error ProofingError Proofing
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Error Proofing
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• So if SPC is not acceptable..
Then?
100% inspection AUTOMATICALLY
ERROR PROOFING
Error ProofingError Proofing
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Error Proofing
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Existing error proofing
Possible defects
Exercise 2Exercise 2
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Exercise 2
Existing Error Proofing andPossible Defects
Existing error proofing and its function:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
Areas where defects often occur and what they are:
_____________________________________________________________________
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_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
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Inspection and Zero Defects
Module 3Module 3
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Who is the best inspector?Who is the best inspector?
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YOUYOU
The User
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Error Proofing
8/18/00
Self-checking - Before handoff
Joint-inspection - During handoff
Successive check - After handoff
Source inspection - Immediately after mistake,
but before it results in a defect
Types of InspectionTypes of Inspection
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Error Proofing
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Three Approaches– Judgment
• Discovers defects after they have happened– Informative
• Reduces defects but doesn’t prevent them– Source
• Catches errors before they cause defects
Types of InspectionTypes of Inspection
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Error Proofing
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An error takes place
Feedback is carried out at error stage
before it becomes a defect
Corrective action is taken accordingly
Source InspectionSource Inspection
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Error Proofing
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1. Source inspection to PREVENT errors before they cause defects
2. 100% inspection using inexpensive devices
3. Action to stop operations when defect is detected
Source InspectionSource Inspection
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1. Build quality into the processes:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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2. All inadvertent errors and defects can be eliminated:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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3. Stop doing it wrong and start doing it right- NOW!
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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4. Don’t think up excuses, think about how to do it right:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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5. A 60% chance of success is good enough, Implement your idea NOW!:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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6. Mistakes and defects can be reduced to ZERO when everyone works together to eliminate them:
• Zero defects• Zero waste• Zero delays
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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7. Ten heads are better than one:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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8. Seek out the true cause using the 8D (disciplines) Process:
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
The Eight Principles of Basic Improvement For Error Proofing and Zero Defects
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Error Proofing
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Step 1: Use team approach
Step 2: Describe the problem
Step 3: Implement short-term corrective action
The 8 Step Problem Solving ProcessThe 8 Step Problem Solving Process
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Error Proofing
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Step 4: Define and Verify root cause(s)
Step 5: Implement permanent corrective action
The 8 Step Problem Solving ProcessThe 8 Step Problem Solving Process
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Error Proofing
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Step 6: Verify effectiveness ofcorrective action
Step 7: Prevent Recurrence
Step 8: Congratulate team
The 8 Step Problem Solving ProcessThe 8 Step Problem Solving Process
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Error Proofing
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Use Team Approach
Congratulate the Team
Implement Short-termCorrective Action
Define and VerifyRoot Causes
Verify Effectivenessof Corrective Action
Describe the Problem
8-D
Implement PermanentCorrective Action
Prevent Recurrence
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Error Proofing
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Operator discovers errorStops process
Quick fix (authorized by Q.A.)Submit operational problem
Team formulated
‘Run’ problem through 8D
Arrive at solution
Apply solution
Error ProofingError Proofing
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Error Proofing Devices
Module 4Module 4
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Error Proofing
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High error potential
Vital characteristics or damage potential
Failure history
Complex operation or much routine detail
Which Operations?Which Operations?
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Describe defect, show defect rate, form
prevention team
Identify location of the defect occurrence
Detail current standards/operating procedures
where defect was made
Identify any deviation from standard
Developing an Error Proofing DeviceDeveloping an Error Proofing Device
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Error Proofing
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Identify red flag conditions (next slide), 5 whys
error happens, until root problem discovered
Identify error proofing device required
Create error proofing device and test for results
CONTINUALLY IMPROVE
Developing an Error Proofing DeviceDeveloping an Error Proofing Device
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Red Flag ConditionsRed Flag Conditions
AdjustmentsTooling and tooling changesDimensions/ specifications/ critical
conditionsMany or mixed partsMultiple steps Infrequent productionLack of an effective standard
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Error Proofing
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SymmetryAsymmetryRapid repetitionHigh / extremely high volumeEnvironmental conditions
Red Flag ConditionsRed Flag Conditions
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Contact method
Fixed-value method
Motion-step method
Warning method
Methods for Using Error Proofing DevicesMethods for Using Error Proofing Devices
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Error Proofing
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Contact Methods
Works by detecting whether a product makes physical or energy contact with
a sensing device
Methods for Using Error Proofing DevicesMethods for Using Error Proofing Devices
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Error Proofing
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Guide pins align flange and also make it impossible to put the flange upside-down
Contact Method ExampleContact Method Example
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Error Proofing
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Contact Method ExampleContact Method Example
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Error Proofing
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Notch in aligns flange
Contact Method ExampleContact Method Example
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Error Proofing
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Rubber O-ring centers tubing
Contact Method ExampleContact Method Example
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Error Proofing
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Notch ensures proper seam alignment for welding
Contact Method ExampleContact Method Example
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Notch is visible showing a correctly
loaded part
Notch is not visible showing an incorrectly
loaded part
Contact Method ExampleContact Method Example
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Error Proofing
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Guide pins align blank for stamping
Contact Method ExampleContact Method Example
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Error Proofing
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Fixed-Value Method
Can be used when a fixed number of parts or operations needs to be performed
Methods for Using Error Proofing DevicesMethods for Using Error Proofing Devices
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Error Proofing
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Counter counts the number of welds made and lights after six welds
Fixed Value MethodFixed Value Method
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Error Proofing
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Motion-Step Method
Used to sense whether a motion or step in the process has been carried out within
a certain expected time
Methods for Using Error Proofing DevicesMethods for Using Error Proofing Devices
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Error Proofing
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Warning Method
Activate a light, buzzer, etc. to signal operator of abnormalities
Methods for Using Error Proofing DevicesMethods for Using Error Proofing Devices
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Error Proofing
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Physical contact sensing devices
Energy sensing devices
Sensors that detect changes in physical
conditions
Types of Sensing DevicesTypes of Sensing Devices
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Error Proofing
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Physical Contact Sensing Devices
Detect the actual presence or lack of presence of a device or part
Types of Sensing DevicesTypes of Sensing Devices
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Error Proofing
968/18/00Touch switch used to sense that the full length of
stock has been fed into the press
No Part Part Present
Physical Contact SensorPhysical Contact Sensor
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Error Proofing
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Contact switch used to detect if a rod is too long
Physical Contact SensorPhysical Contact Sensor
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Error Proofing
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Energy Sensing Devices
Use energy (photoelectric etc.) to determine whether an error is
occurring
Types of Sensing DevicesTypes of Sensing Devices
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Error Proofing
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Photoelectric switches– proper size or color– passage of an object– proper supply of parts– proper feeding of parts
Beam sensorsProximity switches
Energy Sensing DevicesEnergy Sensing Devices
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PhotoelectricPhotoelectric
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Error Proofing
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Change in Physical Conditions
Detect changes in pressure, temperature, electrical current, etc.
Types of Sensing DevicesTypes of Sensing Devices
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Error Proofing
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Pressure
Temperature
Electrical current
pH
Change in Physical ConditionChange in Physical Condition
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Error Proofing
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Problem 1Processing Omissions
Problem:An operator is responsible for drilling six holes.
Sometimes he/she loses count and drills too few holes.
Suggestions To Improve:
Error Proofing – Case StudyError Proofing – Case Study
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Error Proofing
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Problem 2Processing Errors
Problem:In the final assemble/packaging of shocks,
customer part numbers change several times a day, operators sometimes use the incorrect component package.
Suggestions To Improve:
Error Proofing – Case StudyError Proofing – Case Study
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Continuous Improvement Activity SheetContinuous Improvement Activity Sheet
Before Improvement After Improvement
Problem Implemented Item
Team Contact
W. O. #
Date Submitted Date Required Date Completed Champion
Effect
Team Line Facility Idea #
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Brainstorming and proposed solutions
Exercise 3Exercise 3
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Tracking and Identification
Module 5Module 5
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Error Proofing Detailed Description of the Problem Action Taken Date
CompletedPerson
Responsible
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SCRAPGREEN ROD CELL GREEN BODY CELL `
DATE & SHIFT
PIS
TO
N R
OD
S (
2.3
)
WE
LD
ED
RO
D A
SS
Y'S
(2
.6)
INN
ER
CY
LIN
DE
RS
(.
36
)
CO
MP
HE
AD
S (
.30
)
FU
LL
ST
RU
TS
(1
5.5
)
SP
INN
ER
WE
LD
ER
(1
5.5
)
BA
D S
EA
LS
(1
5.5
)
BIN
DE
RS
(1
5.5
)
CU
T I
TC
TU
BE
(2
.)
OU
TE
R B
RK
T A
SS
Y'S
(1
.5)
BO
DY
AS
S'Y
(4
.5)
PR
ES
S (
4.5
)
EN
D C
AP
(4
.5)
PR
OJ
WE
LD
ER
(4
.5)
RO
BO
T (
4.5
)
DIM
PL
ER
(4
.5)
Total
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Hour 1 2 3 4 5 6 7 8 9 10 Total
Seam Split III II IIII II IIIII I II 19
Wrinkles I II I III I III I 12
Bell Split I II II I 6
Tool Marks I III I I 6
Off Gauge II I II 5
Burn Holes I II I III I I III II 14
Porosity I I 2
Burrs IIII I I 6
ID Incorrect I I 2
Ding II I I 4
Sub Total 8 9 9 14 12 9 6 9
Total 76
Tally SheetsTally Sheets
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Counters are attached to the point of use.
Multiple CountersMultiple Counters
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Error Proofing
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Problem: The Cup won’t fit on theTail End of The Tail Pipe.
1. Why?2. Why is the tab too wide?3. Why does it flatten out?4. Why is the temp wrong?5. Why set improperly?
Ask “Why” Five TimesAsk “Why” Five Times
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Error Proofing
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Problem: The bracket on the struts will not hold.
1. Why?2. Why is the weld breaking?3. Why is the bracket misaligned?4. Why is the fixture misaligning the bracket?5. Why is the weld slag built up?
Ask “Why” Five TimesAsk “Why” Five Times
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Error Proofing
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Is a one page chart showing data trends identifying key factors, tracking projects and monitoring
improvements
B.O.S. ChartB.O.S. Chart
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Error Proofing
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B. O. S. charting is a standard tool used to support visual control
One page summary which facilitates management at a glance
Ensures real activities are occurring to improve the areas identified as important to the company
Is an excellent communications tool– to employees– to management
Why Use The B.O.S. Chart Tool?Why Use The B.O.S. Chart Tool?
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Error Proofing
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Key Measurable– Target– Trend Line
ImprovementActivities
Data Analysis– Pareto
ImprovementTracking
B.O.S. Chart FormatB.O.S. Chart Format
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Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec0
50
100
150
200
250
300
Actual Target
0
10
20
30
40
50
Damaged Assembly Cracked Casing
Broken Weld Paint blister
Ref # Description Resp. End Date
1 Redesign finished goods packaging AM 7/18/95
2Procure new component parts
containersJK
6/30/96
3 Improve weld in process weldmonitoring system SL 7/24/95
4Replace current controller on paint
systemGA
9/20/95
Ref # Description Jan Mar May Jul Sept
1 DamagedAssembly 51 48 45 39 5
2 Cracked Casing 20 20 18 20 19
3 Broken Weld 19 17 21 18 1
4 Paint Blister 14 19 18 10 14
B.O.S. Key Measurable: PPMB.O.S. Key Measurable: PPM
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P1
Description ofError Proofing device
P3
Description ofError Proofing device
P2
Description ofError Proofing device
Error Proofing IdentificationError Proofing Identification
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The “P” symbol shall be approximately 3inches (75mm) wide and 4 inches (100mm) tall, and attached on or near the Error Proofing device.
Error Proofing IdentificationError Proofing Identification
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P1
P1 Device(Green)
An Error Proofing device that prevents an error from occurring
Error Proofing Identification* SOURCE INSPECTION *
Error Proofing Identification* SOURCE INSPECTION *
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Error Proofing
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P2
P2 Device(Purple)
An Error Proofing device that detects an error in time to allow rework before it becomes a defect
and prevents further errors of the same type
Error Proofing Identification* INFORMATIVE INSPECTION *Error Proofing Identification
* INFORMATIVE INSPECTION *
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P3
P3 Device(Blue)
An Error Proofing device that detects a defect and eliminates it from the flow of good products
before it reaches the customer.
Error Proofing Identification* JUDGEMENT INSPECTION *Error Proofing Identification
* JUDGEMENT INSPECTION *
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Of the three types of Error
Proofing devices mentioned,
which is the best one to use?
Error ProofingError Proofing
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P1 This does not mean that they all have
to be P1’s, a P3 is better than nothing, but we should continually improve all of the error proofing devices
Continuous ImprovementContinuous Improvement
* SOURCE INSPECTION ** SOURCE INSPECTION *
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Identify where a
– defect is most likely to
occur
– error proofing device is
needed but has not yet
been developed
CRITICAL POINT(Gray)
Critical Operations or PointsCritical Operations or Points
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Error Proofing
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A lot of defective parts could be produced
SCRAP
SC
RA
P
SC
RA
P
SC
RA
P
SCR
SC
RA
P
SCRAP
SCRAP
What happens if an Error Proofing Device Fails?
What happens if an Error Proofing Device Fails?
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Error proofing devices:
– can and do sometimes fail
– need to be checked at the beginning of each
shift
– need to be properly maintained
Maintain the Error Proofing DevicesMaintain the Error Proofing Devices
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Error Proofing
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Keep safety in mind
Understand the function of the device and
what it detects
May need to have a defective part to cycle
and see if defect is detected
Testing Error Proofing DevicesTesting Error Proofing Devices
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Error Proofing
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Label error proofing devices and critical operations
Implementation plan
Exercise 4Exercise 4
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Error Proofing
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Exercise 4
Implementation Plan
Begin immediately, including all cell operatorsUtilize data from the before conditionRemember 60% is good enough for starters
Activities Week 1: Person(s) Responsible
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Activities Week 2: Person(s) Responsible
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Activities Week 3: Person(s) Responsible
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Activities Week 4: Person(s) Responsible
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________