Error Proofing 1 8/18/00 PLANT, MACHINE, OFFICE LAYOUT PEOPLE SUPPORTIVE PRACTICE TOTAL PRODUCTIVE...

Error Proofing

18/18/00

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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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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The process of anticipating, preventing, & detecting errors which adversely affect customers & result

in waste

Error Proofing IsError Proofing Is

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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 will make your job easierand safer!

AnswerAnswer

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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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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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Therefore…

Error Proofing Classes only help us reach our measurables for the overall goals established in our 20 Keys.

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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?

Error Proofing

13

SafetyQuality

–Scrap–PPM–Repairs

Why Error Proofing?Why Error Proofing?

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Light curtains

Safety ExamplesSafety Examples

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Light curtains


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Palm buttons


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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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• 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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• 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


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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?


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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?


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Zero defectsZero wasteZero delays

3 Zeros3 Zeros

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• Error Proofing

1. Simple and inexpensive

2. Automatic, or part of process

3. Placed close to mistake, minimizing damage


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What are some everyday examples?


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Cannot start the car without it being in park

ExamplesExamples

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Dryer stops when you open the door

ExamplesExamples

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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


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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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Five Manufacturing examples– Guide pins– Error detection and alarms– Limit switches– Counters– Checklists


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Guide pins allow only the correct baffle to be loaded in the press

ExamplesExamples

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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


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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


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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


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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


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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


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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


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• So if SPC is not acceptable..

Then?

100% inspection AUTOMATICALLY

ERROR PROOFING


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Existing error proofing

Possible defects


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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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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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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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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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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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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


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2. All inadvertent errors and defects can be eliminated:



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3. Stop doing it wrong and start doing it right- NOW!



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4. Don’t think up excuses, think about how to do it right:



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5. A 60% chance of success is good enough, Implement your idea NOW!:



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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



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7. Ten heads are better than one:



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8. Seek out the true cause using the 8D (disciplines) Process:



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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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Step 4: Define and Verify root cause(s)

Step 5: Implement permanent corrective action


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Step 6: Verify effectiveness ofcorrective action

Step 7: Prevent Recurrence

Step 8: Congratulate team


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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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Operator discovers errorStops process

Quick fix (authorized by Q.A.)Submit operational problem

Team formulated

‘Run’ problem through 8D

Arrive at solution

Apply solution


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Error Proofing Devices

Module 4Module 4

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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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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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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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Contact Methods

Works by detecting whether a product makes physical or energy contact with

a sensing device


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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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Notch in aligns flange


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Rubber O-ring centers tubing


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Notch ensures proper seam alignment for welding


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Notch is visible showing a correctly

loaded part

Notch is not visible showing an incorrectly

loaded part


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Guide pins align blank for stamping


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Fixed-Value Method

Can be used when a fixed number of parts or operations needs to be performed


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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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Motion-Step Method

Used to sense whether a motion or step in the process has been carried out within

a certain expected time


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Warning Method

Activate a light, buzzer, etc. to signal operator of abnormalities


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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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Physical Contact Sensing Devices

Detect the actual presence or lack of presence of a device or part


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stock has been fed into the press

No Part Part Present

Physical Contact SensorPhysical Contact Sensor

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Contact switch used to detect if a rod is too long

Physical Contact SensorPhysical Contact Sensor

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Energy Sensing Devices

Use energy (photoelectric etc.) to determine whether an error is

occurring


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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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Change in Physical Conditions

Detect changes in pressure, temperature, electrical current, etc.


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Pressure

Temperature

Electrical current

pH

Change in Physical ConditionChange in Physical Condition

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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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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


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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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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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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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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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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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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


P2


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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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?


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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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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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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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Label error proofing devices and critical operations

Implementation plan


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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

___________________________________________________________________________

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Error Proofing 1 8/18/00 PLANT, MACHINE, OFFICE LAYOUT PEOPLE SUPPORTIVE PRACTICE TOTAL PRODUCTIVE...

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Transcript of Error Proofing 1 8/18/00 PLANT, MACHINE, OFFICE LAYOUT PEOPLE SUPPORTIVE PRACTICE TOTAL PRODUCTIVE...