Mistake Proofing in Design
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Transcript of Mistake Proofing in Design
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Final Draft.ppt Slide: TBD.1 TRW Automotive 2005
Chapter TBD
Mistake Proofing In Design
Chapter ObjectivesTerminology & Quality System Issues
Assembly Concepts & Constraints
Mistake Prooing Metho!s & "valuation
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Final Draft.ppt Slide: TBD.2 TRW Automotive 2005
Common Terminology
#$A%#esign $or Assembly e!uce costs o assembly activities
#$M%#esign $or Manuacture e!uce costs o component & part abrication
'#$MA( )OT* !irect as well asin!irect costs+
Not u!t "redu#tion$ %& #o!t allo#ation'
Mistake Prooing Poka%,oke or "rror Prooing-Making it !iicult
to make errors in assembly or manuacturing
Part O #$M.#$A activities
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Final Draft.ppt Slide: TBD.( TRW Automotive 2005
Mistake Prooing
Process Control That- Prevent a ailure cause rom arising-or
Prevent a cause rom becoming a ailure )revent a defe#t from o##urrin*
De#ouple #au!e and effe#t
e!uce the occurrence o a ailure cause
/Avoi! Ina!vertent "rrors0-Poka ,oke /,okeru Poka01 2ot aime! at '3illul errors(
Mistake Prooing Can )e SigniicantlyAecte! )y Pro!uct #esign #ecisions 2ot just a manuacturing issue
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Final Draft.ppt Slide: TBD.+ TRW Automotive 2005
Starting Point
e4uires Close Cooperation )et3een#esigners5 Pro!uct "ngineers an!Manuacturing & In!ustrial "ngineers Pro!uct engineers & !esigners must un!erstan!
ho3 !esign !ecisions aect operations
A!!em%l& , fa%ri#ation limitation! mu!t %e #on!idereddurin* de!i*n a#tivitie!
Mistake prooing is not just about manuacturingcontrol-but manuacturing control is the goal
A Pro!uct #esign That Cannot )e Pro!uce!eliably Is 2ot A Successul #esign+
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Final Draft.ppt Slide: TBD.5 TRW Automotive 2005
$oun!ation Concepts
#$SS A!!resses e!uction In 6ariation obust "ngineering5 2oise Management5 #$M"A &
#esign 6eriication Activities
Some 6ariation Arises $rom 'Special Causes( 7ne8pecte! things that occur in manuacturing
7sually !ue to human or machine errors
Mistake Prooing Is A #$SS Tool That *elpse!uce Special Cause 6ariation9 Mistake prooing is !riven by manuacturing
consi!erations Fa%ri#ation , A!!em%l&: )eople , -a#ine!
*o3ever5 mistake prooing can be inluence! &
improve! through pro!uct !esign !ecisions
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Final Draft.ppt Slide: TBD./ TRW Automotive 2005
*uman Constraints1 Shingo
*umans 7nlimite! number o
a8es o motion
'Programme!( 4uickly
an! eiciently-but can
orget the 'program(
6ulnerable to harsh
environments: saety is
a signiicant concern
Minimum maintenance
re4uire! on%site ;ack repeatability:
errors are likely
Mechani
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Final Draft.ppt Slide: TBD. TRW Automotive 2005
Ina!vertent "rrors
"rrors in Manuacturing Are Oten #ue to*uman $actors People are not machines
People inherently lack repeatability
Pro!uct !esigns an! process controls thatignore this are likely to pro!uce non%
conorming goo!s in e8cess o si8 sigma
targets on a regular basis
Can ,ou Count => Pieces epeate!ly? 'All men are liable to error( @ ohn ;ocke
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Final Draft.ppt Slide: TBD. TRW Automotive 2005
Billul "rrors
Operator Ignores ules Consciously chooses to not ollo3 proce!ures
an! use a D3ork%aroun!D instea!
7sually #ue To Process #esign $la3s Or
Poor Maintenance Tape! !o3n limit s3itches
Mirrors on photo sensors
Operators rarely !o this or amusement+ Pro!uction 3orkers & supervisors are ju!ge!
on throughput Sift uota! and !ippin* !#edule!
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Final Draft.ppt
Slide: TBD.3 TRW Automotive 2005
Important Assumptions
Billul "rrors Bill 2ot Occur This is a management issue+
7pstream Operations & Supply ChainActivities Provi!e Materials that Conorm
To #esign Criteria I previous activities are properly mistake
prooe!5 this 3ill generally be true
I upstream activities are !iicult to mistake
proo5 then mistake prooing may be a!!e!!o3nstream
But it 4ill %e le!! effe#tive
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Final Draft.ppt
Slide: TBD.10 TRW Automotive 2005
Mistake Prooing Is 2ecessary
'it became evi!ent that achieving a CpE
F 3oul! go only part o the 3ay Mistake Prooing the !esign 3oul! also be
re4uire! Mistake Prooing the !esign is an
essential actor in achieving the goal o si8
sigma( Smit6 B. 7888 Spe#trum (093 +(;+
"ven A Great Si8 Sigma #esign May )e
Aecte! )y Manuacturing ealities9
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Slide: TBD.11 TRW Automotive 2005
Pro!uct #evelopmentPerspective
Mistake Prooing Must )e Integrate! IntoBorl!%Class Pro!uct eali
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Final Draft.ppt
Slide: TBD.12 TRW Automotive 2005
6eriication & 6ali!ation
6eriication Proves That A #esignConorms To Customer e4uirements #oes not inclu!e manuacturing assumptions
'#6(
6ali!ation $ollo3s 6eriication Proo o manuacturing easibility
Physical !emonstration using 'inal operating
con!itions(
-anufa#turin* pro#e!! , intended u!e
-i!ta>e proofin* inte*rate! de!i*n , manufa#turin*
i!!ue! in validation
'P6(
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Final Draft.ppt
Slide: TBD.1( TRW Automotive 2005
G#PIM Outline
Integrate #$A Into C6 & #6 Activities Mistake prooing is also critical to Process #esign
)eriperal effe#t on D< %ut #riti#al effe#t on )