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PLANT,

SUPPLIER. DEVELOPMENT. PLANT,. MACHINE,. OFFICE. LAYOUT. PEOPLE SUPPORTIVE PRACTICE. LEAD TIME. 20. REDUCTION. KEYS. LEVELING/ SMALL LOT. EMPLOEE INVOLVEMENT/ WHITE SHIRT. * People Excellence * Production Excellence * Business Excellence . PROCESS

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PLANT,

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  1. SUPPLIER DEVELOPMENT PLANT, MACHINE, OFFICE LAYOUT PEOPLE SUPPORTIVE PRACTICE LEAD TIME 20 REDUCTION KEYS LEVELING/ SMALL LOT EMPLOEE INVOLVEMENT/ WHITE SHIRT * People Excellence * Production Excellence * Business Excellence PROCESS CAPABILITY SIX SIGMA Pull System Quick Set-up TOTAL PRODUCTIVEMAINTENANCE CONTAINER -IZATION/ TRANSPOR- TATION WPO & VISUALMANAGEMENT Error Proofing Error

  2. Goals To understand the principles of ERROR PROOFING, the reasoning behind it, and the processes of developing Error Proofing (poka-yoke) devices

  3. Objectives • 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

  4. Error Proofing Is The process of anticipating, preventing, & detecting errors which adversely affect customers & result in waste

  5. Questions Will Error Proofing be more work to complicate our jobs even further? How does Error Proofing fit in the AMPS program?

  6. Answer Error Proofing will make your job easier and safer!

  7. How can the Error Proofing class be used? • Catalyst for improvement • Tool for reaching measurables • Learning device

  8. What Measurables does Error Proofing affect? • PPM • Scrap • Process Capability

  9. Other Benefits • Safety Improvements • Quality Improvements • Ergonomic Benefits • Promotes Design for Manufacturing

  10. Therefore… Error Proofing Classes only help us reach our measurables for the overall goals established in our20 Keys.

  11. Error Proofing Think – Quality Think – Right First Time Think – Zero Defects

  12. Why Error Proofing? • Maintain customer satisfaction • Reduce cost • Ability to maintain Continuous Improvement production methods and smaller inventories

  13. Why Error Proofing? • Safety • Quality • Scrap • PPM • Repairs

  14. Safety Examples Light curtains

  15. Safety Examples Light curtains

  16. Safety Examples Palm buttons

  17. 1-100-1000 Rule 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?

  18. Error Proofing Directly Affects 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

  19. Parts Per Million • 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.

  20. Parts Per Million • 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

  21. Parts Per Million • 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?

  22. Parts Per Million • 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?

  23. 3 Zeros Zero defects Zero waste Zero delays

  24. Error Proofing • Error Proofing • 1. Simple and inexpensive • 2. Automatic, or part of process • 3. Placed close to mistake, minimizing • damage

  25. Error Proofing What are some everyday examples?

  26. Examples Cannot start the car without it being in park

  27. Examples Dryer stops when you open the door

  28. Examples Mower stops when you release the handle

  29. Inside the Refrigerator Light goes out when you shut the door

  30. Exercise 1 List examples of error proofing in room

  31. Module 2 Error Proofing Devices and Defects

  32. Error Proofing • 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

  33. Error Proofing Devices Simple and inexpensive devices that are used to prevent errors about to occur or detect errors and defects that have occurred.

  34. Errors 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

  35. Error Proofing • Five Manufacturing examples • Guide pins • Error detection and alarms • Limit switches • Counters • Checklists

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

  37. Examples Guide pins are used to check alignment of the flange.

  38. Examples Assembly/Mounting Error

  39. Examples Limit Switch

  40. Ten Causes of Errors • 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

  41. Ten Causes of Errors • Missing parts • Not all parts included in the assembly, welding, or other processes • Improper part/item • Wrong part installed in assembly • Processing wrong work piece • Wrong part machined

  42. Ten Causes of Errors • 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

  43. Ten Causes of Errors • Errors in equipment maintenance or repair • Defects caused by incorrect repairs or component replacement • Errors in preparation of blades, jigs, or tools • Damaged blades, poorly designed jigs, or wrong tools

  44. Five Causes of Human Errors • 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

  45. Traditional Management Cycle • Error takes place • A defect occurs as a result • This information is fed back • Corrective action is taken accordingly

  46. Traditional Alternatives • 100% Inspection • SPC SPC

  47. Error Proofing • 100% Inspection • -Costly • -Non-Value Added • -Not fail-safe

  48. SPC Good Part Are These Acceptable?

  49. Error Proofing • 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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