【正文】 p 傳遞 a Defect! 缺陷！ Living Up to the Motto… 達到口號 “ Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place‖ Dr. Deming PFMEA Workstation Readiness 工位準備 Process Control Plan 工藝控制計劃 Errorproofing Plan 防錯計劃 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 32 GMS Error Proofing Hierarchy 防錯層次 Prevention 預防 Detection 檢測 Human Judgment 人為判斷 None 無 Product / Process Design Change 產品 /工藝設計改變 ? DFM/A D/PFMEA ? Robust Designs Capable Processes 機器設計及可行工藝 ? OneWay Assembly 同一裝配 ?Process Controls 工藝控制 ?Locating Pins Stops 固定點及停點 ?Sensors Process Monitors 傳感器及工藝監(jiān)控 ?Electro Mechanical Devices 電子機械儀器 ?Color Coding 顏色信號 ?Visual Controls 直觀控制 ?Andon Systems 暗燈系統(tǒng) ?Standardized Work 標準化工作 Errors Can’t Happen Small Improvement 小改進 Significant Improvement 重大改進 Introduction to Error Proofing 防錯介紹 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 33 GMS 0 5 15 10 0 3 9 6 O L H M 5 10 20 15 0 15 10 1 2 4 5 7 8 10 11 5 0 5 15 10 0 3 9 6 O L H M 5 10 20 15 0 15 10 4 5 7 8 10 11 5 1 2 Original: Best: Visual Control Example Human Judgment 0 5 15 10 0 3 9 6 O L H M 5 10 20 15 0 15 10 1 2 4 5 7 8 10 11 5 Better: GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 34 GMS A B Example: Vehicle Identification 車輛認證 (Mutilation Cover Color) (蓋板顏色毀損 ) Human Judgment 人為判斷 Visual Control Example GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 35 GMS Vertical Plate 垂直板 Battery Post 電池接頭 Process Control Example Detection 檢測 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 36 GMS X Work Piece 加工件 Work Piece 加工件 Fixture 夾具 Fixture 夾具 Process Control Example Prevention 預防 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 37 GMS Product Design Example (Before) REC STOP PAUSE REC STOP PAUSE OLD DESIGN 老設計 Can be Installed Upside Down 可以反安裝 Application of Labels on Cassette Prevention 預防 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 38 GMS REC STOP PAUSE NEW DESIGN 新設計 Application of Labels on Cassette Can Only Be Installed Correctly! Product Design Example (After) Prevention GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 39 GMS Left Hand Locator Tab Right Hand Locator Tab Example Product Error Proofing (One Way to Install Seat Belt) 防錯樣品 —只有一種安全帶安裝方法 Product Design Example 產品設計范例 Prevention GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 40 GMS Simple Everyday Examples 1) Error Prevention ?? ?? Automatic shutoff 自動斷電 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 41 GMS Error Proofing Exercise ? Think of an example at work or at home where error proofing can prevent an undesirable thing from happening 想想工作或生活中使用防錯措施避免不好事情發(fā)生的例子 ? Discuss as a team and report – Take 5 minutes 小組討論、匯報 —5分鐘 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 42 GMS Manufacturing Process Validation Product Quality Standards Quality System Management Quality Feedback/ Feed forward Standardized Work Visual Management Management by TAKT Time Work place Organization Andon Concept Problem Solving Continuous Improvement Process Lean Design of Facilities, Equipment, Tooling and Layout Business Plan Deployment Total Productive Maintenance Controlled External Transportation Scheduled Shipping / Receiving Level Vehicle Order Schedules Supply Chain Management Internal Pull / Delivery Simple Process Flow Small Lot Packaging Fixed Period Ordering System/ Order Parts Health and Safety Priority Team Concept People Involvement Open Communication Process Values Vision/ Mission Shop Floor Management InProcess Control Verification 工序控制與認證 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 43 GMS InProcess Control Verification – (3) Elements 工序控制與認證 1. Prevention Outputs 輸出 Inputs 投入 NOK 2. Detection OK Next Process 下道工序 Feedback 反饋 Do not 不要 Accept 接受 Build 制造 Ship 傳遞 a Defect! 缺陷！ Living Up to the Motto… 符合標準 3. Containment 包容 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 44 GMS 1) Standardized Work 標準化工作 Follow and Continuously Improve Standardized Work!!! 遵守及不斷 改進標準化工作??！ InProcess Control Verification – 1) PREVENTION Prevention Vehicle Manifest Manual 2Door Sunroof GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 45 GMS 2) Focus on Operation 集中精力生產 Keep Your Concentration Respect Standardized Work of Others! 注意及尊重他人的 標準化工作 InProcess Control Verification – 1) PREVENTION Prevention GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 46 GMS 3) Error Proofing Prevention Operator Aids 防錯預防與操作者支持 The Best Process is One That Cannot Fail! 最好工序就是不會失敗的！ InProcess Control Verification – 1) PREVENTION Prevention DAEWOO GMS Orientation