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Error Proofing Techniques
Error Proofing Techniques
Techniques
ERROR PROOFING TECHNIQUES
AGENDA
Reduced
Handling = 120 ppm
QUALITY MEASURE
Visual
Management = 100 ppm
Error
Proofing = 80 ppm
Preventative
Maintenance = 60 ppm
TARGET
TIME
TIME FRAME OF
ACTION PLANS
© Copyright General Motors. All rights reserved.
MAKE ALL PEOPLE DEFINE
AFFECTED AWARE CURRENT
PROJECT OF WHAT IS SITUATION
SELECTION GOING TO HAPPEN
• CUSTOMER QUALITY CONCERN
SELECT • PROCESS FLOW & DATA WORKSHEETS
• HIGH RPPM / REPEAT PR/R’s
• PART IN CONTROLLED SHIPPING
• CHRONIC QUALITY PROBLEM
TEAM MEMBERS •
•
QUALITY RESULTS
PROCESS MEASURES
• GM PRODUCT/PROCESS ENGINEER • PROBLEM DEFINITION
• HIGH WARRANTY IMPACT
• SUPPLIER PERSONNEL (ENGR., MFG,
• HIGH COST OF QUALITY
QUALITY, OPERATORS, ETC)
• PURCHASING
• SUPPLIER QUALITY ENGINEER
• CUSTOMER REPRESENTATIVE
IDENTIFY
LOOK FOR NEW
POSSIBLE
OPPORTUNITIES
CAUSES
Process
• BRAINSTORMING
• 5 WHY’s
• CAUSE & EFFECT DIAGRAM
• STORYBOARD
• COLLECT THE DATA
• RUN CHARTS
• FREQUENCY DISTRIBUTION
• PICTOGRAPH
RECOGNIZE • SCATTER DIAGRAMS
• PROCESS CAPABILITY STUDY
PEOPLE
EVALUATE
AND ADJUST
OPERATION:
FROM:___________________________ QUANTITY PER SHIFT:______________ CUSTOMER CYCLE TIME:__________________
1 5
ANALYZE THE DATA
2
3
4
PLAN & IMPLEMENT SELECT GOOD IDEAS
WORKSTATION AREA DRAWN TO SCALE
03/23/94
CORRECTIVE ACTION • GATHER NEW DATA AS NECESSARY.
• DEVELOP ACTION PLANS FOR CONTAINMENT,
CORRECTION, AND PREVENTION.
• EVALUATE EFFECTIVENESS OF THE • BASED ON PROFOUND KNOWLEDGE • DOCUMENT RECOMMENDED CHANGES AND
ACTION PLANS. • OVERCOMING ROADBLOCKS ACTION PLANS.
• MEDIAN & RANGE CHARTS • ACTION PLANS PROCESSED ASAP • ESTABLISH IMPLEMENTATION TIMING AND
• AVERAGE & RANGE CHARTS
RESPONSIBILITY.
• PROCESS CAPABILITY
WHAT IS AN ERROR???
• Forgetting to stop
• Misassembled Parts
– Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...
• Incorrect Processing
– Disposing of a part rejected at test to the wrong pile
• Incorrect Parts
– Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...
WHAT ABOUT ERRORS AT WORK?
INJURIES
LOST
EFFECTS OF PROBLEM
CUSTOMER SUPPLIER
WHY DO HUMAN
ERRORS OCCUR
WHEN EVERYONE
IS FOR QUALITY?
WHY DO ERRORS
HAPPEN?
The quality of an operator dependent process is affected by the:
Knowledge (Skill)
Operator
Vigilance (Attention to detail)
BUT.....
Relief Breaks
Rotation
Overtime
Coverage Various People Doing Only One Job!!!!
Shift-Shift
Transfers Various:
Levels of Training
Farm-Ins Knowledge of Total Product
Knowledge of Customer Requirements
Methods of Performing Job
People
People Variation
Variation
Relief Breaks
KNOWLEDGE
Rotation
Overtime
Coverage Various People Doing Only One Job!!!!
Shift-Shift
Transfers Various:
Levels of Training
Farm-Ins Knowledge of Total Product
Knowledge of Customer Requirements
Methods of Performing Job
People
People Distractions
Distractions
Machine’s down...
What are you doing tonight?
OOPS!!!!!!
People
People Distractions
Distractions
VIGILANCE
This is how this job goes... Boredom
Machine’s down...
What are you doing tonight?
OOPS!!!!!!
WHY ARE MISTAKES A PROBLEM?
Cost us money
Cost us time
This
Thisisiswhere
wherethe
theconcept
conceptof
of
ERROR
ERRORPROOFING
PROOFING
comes
comesin.......
in.......
A SYSTEM IS NEEDED
TO COMBAT THESE DRAWBACKS:
BENEFITS
Assures 1st Piece Quality
Assures Consistency during Set-Ups
Prevents Production of Defective Parts
Makes Quality Problems More Visible
Creates a Safer Work Environment
Eliminates Waste of Inspection and Repair
Lowers Cost of Design (DFM) and Cost to
Manufacture (Poka-Yoke Devices)
ERROR PROOFING TECHNIQUES
OBJECTIVE
Reduced
Handling = 120 ppm
QUALITY MEASURE
Visual
Management = 100 ppm
Error
Proofing = 80 ppm
Preventative
Maintenance = 60 ppm
TARGET
TIME
TIME FRAME OF
ACTION PLANS
© Copyright General Motors. All rights reserved.
MAKE ALL PEOPLE DEFINE
AFFECTED AWARE CURRENT
PROJECT OF WHAT IS SITUATION
SELECTION GOING TO HAPPEN
• CUSTOMER QUALITY CONCERN
SELECT • PROCESS FLOW & DATA WORKSHEETS
•
•
•
HIGH RPPM / REPEAT PR/R’s
PART IN CONTROLLED SHIPPING
CHRONIC QUALITY PROBLEM
TEAM MEMBERS •
•
QUALITY RESULTS
PROCESS MEASURES
• GM PRODUCT/PROCESS ENGINEER • PROBLEM DEFINITION
• HIGH WARRANTY IMPACT • SUPPLIER PERSONNEL (ENGR., MFG,
• HIGH COST OF QUALITY
QUALITY, OPERATORS, ETC)
• PURCHASING
• SUPPLIER QUALITY ENGINEER
• CUSTOMER REPRESENTATIVE
IDENTIFY
LOOK FOR NEW
POSSIBLE
OPPORTUNITIES
CAUSES
• BRAINSTORMING
Process •
•
•
5 WHY’s
CAUSE & EFFECT DIAGRAM
STORYBOARD
• COLLECT THE DATA
• RUN CHARTS
• FREQUENCY DISTRIBUTION
• PICTOGRAPH
RECOGNIZE • SCATTER DIAGRAMS
• PROCESS CAPABILITY STUDY
PEOPLE
EVALUATE
AND ADJUST
OPERATION:
FROM:___________________________ QUANTITY PER SHIFT:______________ CUSTOMER CYCLE TIME:__________________
TO: _____________________________ SHIFT:________ OPERATOR CYCLE TIME:__________________
DESCRIPTION OF ELEMENT TIME STANDARD IN- QUALITY CRITICAL
NO. OPERATION HAND WORK
MACHINE
WALK PROCESS STOCK Q CHECK C OPERATION
SAFETY
1 5
ANALYZE THE DATA
2
3
4
PLAN & IMPLEMENT SELECT GOOD IDEAS
WORKSTATION AREA DRAWN TO SCALE
03/23/94
CORRECTIVE ACTION • GATHER NEW DATA AS NECESSARY.
• DEVELOP ACTION PLANS FOR CONTAINMENT,
CORRECTION, AND PREVENTION.
• EVALUATE EFFECTIVENESS OF THE • BASED ON PROFOUND KNOWLEDGE • DOCUMENT RECOMMENDED CHANGES AND
ACTION PLANS. • OVERCOMING ROADBLOCKS ACTION PLANS.
• MEDIAN & RANGE CHARTS • ACTION PLANS PROCESSED ASAP • ESTABLISH IMPLEMENTATION TIMING AND
• AVERAGE & RANGE CHARTS
RESPONSIBILITY.
• PROCESS CAPABILITY
Error Proofing Techniques
Agenda
LOST
EFFECTS OF PROBLEM
CUSTOMER SUPPLIER
WHY ARE MISTAKES A PROBLEM?
Cost us money
Cost us time
Error
ErrorProofing
Proofingis
isthe
theactivity
activityof
ofawareness,
awareness,detection,
detection,and
and
prevention
preventionof
oferrors
errorswhich
whichadversely
adverselyaffect:
affect:
Our
Ourcustomers
customers (defects)
(defects)
Our
Ourpeople
people (injuries)
(injuries)
and
andresult
resultin
inWASTE!
WASTE!
Awareness: Having the forethought that a mistake can be made, communicating the potential, and
planning the design of the product or process to detect or prevent it.
Detection: Allowing the mistake to happen but providing some means of detecting it and alerting
someone so that we fix it before sending it to our customer.
Prevention: Not allowing the possibility for the mistake to occur in the first place.
ERROR PROOFING
Techniques
• Design for Manufacturability
• “Poka-Yoke” System Devices
ERROR PROOFING
Techniques:
• Design For Manufacturability (DFM)
Technique that Results in Designs that Cannot
be Incorrectly Manufactured or Assembled.
This Technique can also be used to “Simplify”
the Design and therefore reduce its cost.
ERROR PROOFING
Techniques (Continued)
• “Poka-Yoke” System*
Set-Up Devices or Inspection Techniques that Assure that
Set-Up is Done Correctly; i.e. Produces 100% Good Parts
from the First Piece on
“Zero Quality Control: Source Inspection and the Poka-Yoke System” - Shigeo Shingo; 1986
EXAMPLES OF ERRORS AT WORK . . .
Missing Parts
Forgetting to assemble a part - screws, labels, orifice tubes...
Misassembled Parts
Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...
Incorrect Processing
Disposing of a part rejected at test to the wrong pile
Incorrect Parts
Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...
Identify Error Proofing Opportunities
• PFMEA
IDENTIFY • Quality Data, PR/R, Warranty Data...
• Brainstorm (Questions to Ask, Free Form...)
Problem
BENEFITS
SENSOR INFORMATION:
BASIC TYPES OF SENSORS
• Discrete sensors
• Analog sensors
DISCRETE SENSORS
• The part is present or is not present.
• Most frequently asked question in a manufacturing
operation.
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
NO PHYSICAL CONTACT
• Advantages - No physical contact
- Better for counting sensitive surfaces,
e.g. painted or polished surfaces
- No moving parts
- Faster
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
INDUCTIVE
• Based on metal targets; will not respond
to non-metallic targets with high reliability.
CAPACITIVE
• Cannot distinguish between the real target
and something else in the target region.
Must control what comes close to the target.
PHOTOELECTRIC
• Can be fooled by a non-target.
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
• Method of Application:
• All materials are sensed through a change on the
dielectric characteristics.
• Ideal applications include bulk materials and liquids
in containers of glass and plastic.
• Characteristics:
• Poor choice for metal targets.
• Is very sensitive to environmental factors.
• Sensing range depends greatly on the material being
sensed.
• Can be misled and therefore it is important to control
the material which is presented to the sensor.
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Photoelectric Sensors
THRU
Emitter Receiver
Target
Thru: Advantages:
• Light source (emitter) and 1. Most reliable when target is opaque
receiver are placed opposite 2. Long range scanning, most excess gain
each other. 3. Use in high contamination areas, dirt, mist,
• The object to be detected condensation, oil film, etc.
passes between the two. 4. Precise positioning or edge-guiding of opaque
material
5. Parts counting
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors
Photoelectric Sensors
Target
Diffuse: Advantages:
• Light beam is directed at the 1. No reflector required.
object to be detected. 2. Convenient for installation.
• Light will be reflected off the 3. One sided scanning.
object in many directions.
4. Senses clear materials when
• Some of the light reflected from distance is not fixed.
the object will be sensed by the
5. Ease of alignment
receiver.
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Background suppression utilizes 2 receivers behind the receiving lens. They are
aimed at a precise point in front of the unit and sense the presence of a target
when the output of both receives are equal.
Applications:
Photoelectric Sensors
Reflector
Retroreflective
Target
Retroreflective: Advantages:
• Light beam is directed at a reflective target 1. One-sided scanning
(reflector, tape or other reflective object) - 2. Ease of alignment
one which returns light along the same
3. Immune to vibration
path it was sent.
• The object to be detected passes between
photoelectric control and reflective target.
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors
Photoelectric Sensors
Convergent Beam
Fixed
Distance Target
Convergent: Advantages:
• Light beam is directed at object to be 1. First choice for detecting clear
detected (ignores background materials
surfaces) 2. Ignores unwanted background
• Object must be at a given distance in surface reflection
relationship to photoelectric control 3. Detects objects with low reflectivity
before light will be reflected to receiver
4. Detects height differential
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Photoelectric Sensors
Thru
Target or
Reflector
Fiber Optic:
• Not a scanning technique but rather another way of transmitting light beam.
Advantages:
1. High temperature applications 4. Corrosive areas
2. Where space is limited 5. Noise immunity
3. Size and flexibility of fiber leads 6. Color sensing
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
Types of Non-Contact Sensors
Photoelectric Sensors
Special
Reflector
Polarized
Target
Polarized: Advantages:
• Will work only with comercube 1. One-sided sensing
reflector or special polarized 2. Does not false trigger off
reflective tape. highly reflective object
• Will not false trigger when 3. Senses clear materials
sensing shiny object. 4. Ease of alignment
5. Immune to vibration
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
APPLICATIONS FOR PHOTOELECTRIC SENSORS
APPLICATION SCAN TECHNIQUE
Small parts detection Fiber optics or Thru scan with aperatures
Long distance scanning Thru scan
High temperature sensing Fiber optic
Shiny object or film detection Polarized scan
Severe environment (Extreme dust or dirt) Thru scan
Limited mounting space Fiber optic
Explosive environment Thru scan or Retro
Washdown environment Thru, Retro-reflective or Diffuse
Analog position sensing Diffuse or Fiber Optic
Conveyor Monitor Polarized, Diffuse or Retro
- Jam detection
- Part count
- Part position
Vibratory Feeder Fiber optic
Lid or Cap detection Convergent beam or Fiber Optic
Clear bottle detection Polarized or Fiber Optic
Transparent material Polarized scan
Label detection Diffuse or Fiber Optic
Bin or hopper level Thru when using window Diffuse from above
Mold or die clear to close Thru scan or Fiber Optic (high temp)
Max height monitor (i.e. Fork trucks) Thru scan
Opaque material on semitransparent carrier Thru scan
Motion detection All scan type
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
ADVANTAGES DISADVANTAGES APPLICATIONS
Magnet Operated - Inexpensive - Magnet required - Security and safety
(reed relay) - Very selective target - Sensitive to welding interlocking
identification fields - Sensing thru metal
Capacitive - Senses all materials - Very sensitive to - Level sensing with liquids
- Detects through walls environment changes and non-metallic parts
NEW APPLICATIONS:
• Pressure sensing
• Shape sensing
• Weight sensing
• Presence sensing
• Color sensing (dark vs light)
• Torque sensing (Piezo-electric)
• Position sensing
• Custom / adaptive size parts
• Vacuum sensing
• Flow sensing (e.g. gallon / minute)
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
8. Pressure Sensor
ERROR-PROOFING TECHNIQUES
(Poka-Yoke) CONCEPT
EXAMPLES OF POKA-YOKE’S
FOR THE THREE MOST COMMON PROBLEMS
Error Proofing Type of Type of
Problem Type
Installed Sensor Used Intervention Used
Missing Components Counter to verify Micro-switch Machine interlock
correct number of
components
Missing Parts
– Is there a model mix such that some models require a
part while others require nothing at all in that location?
Misassembled Parts
– Is the operation difficult for the operator to see
as they perform the job?
NO
Implement Error Proofing
What can be done to detect whether
What can be done to detect whether (process/design change and/or
the part has been misassembled?
the part has been misassembled? detect/lock out device)
Detection device - torque counter,
Detection device - torque counter,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch
GOOD REJECTS
Incorrect
Incorrect Processing
Processing
Does the operation require recognition
Does the operation require recognition
of some characteristic to determine
of some characteristic to determine
what to do with the part? Implement operator instructions,
what to do with the part?
NO visual aids and training as minimum
(e.g. Red light indicates place in reject requirement
(e.g. Red light indicates place in reject
pile, visual inspection for pre-defined
pile, visual inspection for pre-defined
defects)
defects)
YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process?
in design of product/process?
(fixtures, automation)
(fixtures, automation) YES
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?
NO
What can be done to detect whether
What can be done to detect whether Implement Error Proofing
the part has been incorrectly
the part has been incorrectly (process/design change and/or
processed?
processed? detect/lock out device)
Detection device - reset button,
Detection device - reset button,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch
• Visual aids
– Quality alert indicating high potential for error
– Fixture or template outlining pre-defined defects
– Bogey or sample boards for visual inspection
• Redefine process
– Reset or acknowledge but at the appropriate next operation
– Automate
• Workplace organization
– Separate and clearly label reject locations/containers
• Sensors
– Photoelectric eyes to detect, lock out until corrected
– Limit switch to detect, lock out until corrected
Four Categories of Errors-Questions to Ask????
Incorrect Parts
Is there a selection of parts in front of the operator that
would allow for the wrong part to be chosen and
assembled?
Incorrect
Incorrect Parts
Parts
Is there a selection of parts available
Is there a selection of parts available
at the workstation?
at the workstation?
Are similar parts assembled onto the Implement operator instructions,
Are similar parts assembled onto the
product at the same location? NO visual aids and training as minimum
product at the same location?
requirement
YES
Can anything be done to resolve this
Can anything be done to resolve this
in design of product/process?
in design of product/process?
(Consolidation, separate operations)
(Consolidation, separate operations) YES
Can the part be combined with
Can the part be combined with
another part?
another part?
Can the part be eliminated?
Can the part be eliminated?
NO
What can be done to detect whether
What can be done to detect whether Implement Error Proofing
the incorrect part has been
the incorrect part has been (process/design change and/or
assembled?
assembled? detect/lock out device)
Detection device - bar code,
Detection device - bar code,
photoelectric eye, limit switch Verify results
photoelectric eye, limit switch
First Time
Systematic Departmental
Quality Internal Customer
Problem Containment Warranty
(F.T.Q.) Plant Rejects
Solving Station Information
at Audit (PPM)
Process Network
Operation
Institutionalize
the Solution
and the Ongoing
Control
Continuous
Institutionalize Opportunity
Improvement
Problem Solving Documentation
Prevent Select
5. Evaluate 1. Identify
1% 1%
Defect Defect
Rate 1% Rate 1%
1% 1%
Defect Defect Defect Defect
Rate Rate Rate Rate
Cell 4 Cell 3
1% 1% 1% 1%
Defect Defect Defect Defect
Rate Rate Rate Rate
RESULTS IN 78%
CONFORMING PRODUCTS
PROCESS FALLOUT TABLE
Centered Process
Misunderstanding
Non-Supervision
Misidentification
Human
International
Errors
Inadvertent
Amateurs
Slowness
Surprise
Forgeful
Causes
Willful
of Defects
Omitted Processing
Processing Errors
Errors Setting Up Workpieces
Missing Parts
Wrong Parts
Processing Wrong Workpiece
Misoperation
Adjustment Error
Improper Equipment Setup
Improper Tools and Jigs
SOURCE: NKS/Factory Magazine “Poka-Yoke”
ERROR PROOFING TECHNIQUES
WORKSHOP OBJECTIVE
SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:___________________________________________________________________
PROCESS:_________________________________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:___________________________________________________________
AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST
_________________
ACTUAL
FIRST TIME
QUALITY
FORECAST
_________________
ACTUAL
PROCESS
CAPABILITY
FORECAST
_________________
ACTUAL
OVERALL QUALITY
MEASURE
FORECAST
_________________
ACTUAL
COMMENTS:
Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.
TEAM LEADERS:
PHONE:
• Management Support
• Team Members who:
• Are team players
• Communicate well
• Not afraid to contribute
• Are empowered
• Have the desire to solve problems
• Can make it happen
Error Proofing Techniques
TEAM RECOMMENDATION
KEY AREAS:
• OPERATORS & INSPECTORS FROM STUDY
AREA
• PROCESS AND DESIGN ENGINEER
• QUALITY REPRESENTATIVE
• SKILLED TRADES
OPTIONAL AREAS:
• MAINTENANCE REPRESENTATIVE
Page 1 of 2
CHECKLIST
STATUS ITEM
WORKSHOP WORKSITE INFORMATION PROVIDED/AVAILABLE:
- PLANT LAYOUT OF WORKSITE AREA SHOWING PRODUCT FLOW AND OPERATORS (ON 8 1/2 X 11 PAPER).
- CUSTOMER SPECIFICATIONS AND REQUIREMENTS.
- EQUIPMENT PROCESS CAPABILITY AND PERFORMANCE RECORDS AVAILABLE.
- INTERNAL PLANT AUDIT INFORMATION.
- CUSTOMER REJECTIONS BY TYPE AND CAUSE
- REJECTION RATE (IN-PROCESS SCRAP)
- SETUP REQUIREMENTS (PEOPLE & TIME)
- CHANGEOVER TIME
- EQUIPMENT DOWNTIME OR UPTIME
- PFMEA DATA
- PROCESS FLOW INFORMATION AND CONTROL PLAN DATA
DRESS CODE ESTABLISHED AS CASUAL PLUS PLANT SAFETY REQUIREMENTS (E.G. HARD SOLE SHOES, LONG SLEEVES, ETC).
TRANSPARENCY DESCRIBING ADMINISTRATIVE DETAILS:
- LAYOUT AND LOCATION OF CONFERENCE ROOMS.
- REST ROOM LOCATIONS.
- LUNCH ARRANGEMENTS
- LIST OF ATTENDEES/PARTICIPANTS BY NAME, COMPANY, AND TITLE
- SAFETY REQUIREMENTS
- MESSAGE CENTER(S)
- PHONE LOCATIONS
- SMOKING REGULATIONS (NO SMOKING IN CONFERENCE AND TEAM ROOMS REQUESTED)
FINALIZE OPENING KICKOFF SPEAKER IDENTIFICATION, TIMING, AND CONTENT.
MTG ARRANGED FOR END OF EACH DAY WITH TOP MANAGEMENT AND TEAM LEADERS TO REVIEW STATUS/ADDRESS ROADBLOCKS.
LOGISTIC ARRANGEMENTS MADE TO ALLOW GM PERSONNEL TO DRIVE DAILY ON PLANT PROPERTY TO WORKSITE/MEETING ROOMS.
Page 2 of 2
ERROR PROOFING TECHNIQUES
ATTENDEES
NAME COMPANY CURRENT JOB ASSIGNMENT BUSINESS PHONE
Workshop Action Items
Supplier: Location:
SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:___________________________________________________________________
PROCESS:________________________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:___________________________________________________________
AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST
_________________
ACTUAL
FIRST TIME
QUALITY FORECAST
_________________
ACTUAL
PROCESS
CAPABILITY FORECAST
_________________
ACTUAL
OVERALL QUALITY
MEASURE FORECAST
_________________
ACTUAL
COMMENTS:
Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.
TEAM LEADERS:
PHONE:
DEFINE CURRENT STATE
• AREAS OF INVESTIGATION AND CONFIRMATION:
EPFORM-L.PPT Pg.1
02/13/00
Workshop Action Items
Supplier: Location:
SUPPLIER:__________________________________________________________________________________
GM SPONSORING DIVISION:_____________________________________________________________
PROCESS:________________________________________________________________________________________________________________________________
PPAP REQUIREMENTS ADDRESSED (Y/N):____________________________
CREATIVITY TEAM NAME & NUMBER:_____________________________________________________
AFTER WORKSHOP
PARAMETERS BEFORE IMPROVED STATE (CURRENT WEEK) SHORT TERM (0-6 MOS) LONG TERM (6-12 MOS)
WORKSHOP MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT MEASURE % IMPROVEMENT
COST OF
QUALITY FORECAST
_________________
ACTUAL
FIRST TIME
QUALITY FORECAST
_________________
ACTUAL
PROCESS
CAPABILITY FORECAST
_________________
ACTUAL
OVERALL QUALITY
MEASURE FORECAST
_________________
ACTUAL
COMMENTS:
Please indicate the measures used: Examples of Cost of Quality improvements = reduced / eliminated scrap &/or rework, reduction of excess inventory.
(Not all measures need to be used during workshop) First Time Quality = improvement in end of line quality results.
Process Capability = improvement in process capability.
Overall Quality Measure = defects per part or rrppm.
TEAM LEADERS:
PHONE:
WHAT IS
ERROR
PROOFING?
HOW AND
WHERE DO WE
APPLY IT?
WHAT IS ERROR PROOFING?
Error
ErrorProofing
Proofingis
isthe
theactivity
activityof
ofawareness,
awareness,detection,
detection,and
and
prevention
preventionof
oferrors
errorswhich
whichadversely
adverselyaffect:
affect:
Our
Ourcustomers
customers (defects)
(defects)
Our
Ourpeople
people (injuries)
(injuries)
and
andresult
resultin
inWASTE!
WASTE!
Awareness: Having the forethought that a mistake can be made, communicating the potential, and
planning the design of the product or process to detect or prevent it.
Detection: Allowing the mistake to happen but providing some means of detecting it and alerting
someone so that we fix it before sending it to our customer.
Prevention: Not allowing the possibility for the mistake to occur in the first place.
WHY DO WE SUGGEST ERROR PROOFING?
OMITTED PROCESSING
PROCESSING ERRORS
ERRORS SETTING UP WORKPIECES
MISSING PARTS
WRONG PARTS
PROCESSING WRONG WORKPIECE
MISOPERATION
ADJUSTMENT ERROR
EQUIPMENT NOT SET UP PROPERLY
TOOLS AND JIGS IMPROPERLY PREPARED
DIFFERENT KINDS OF ERRORS
FORGETFULNESS
ERRORS DUE TO MISUNDERSTANDING
ERRORS IN IDENTIFICATION
ERRORS MADE BY AMATEURS
WILLFUL ERRORS
INADVERTENT ERRORS
ERRORS DUE TO SLOWNESS
ERRORS DUE TO THE LACK OF STANDARDS
SURPRISE ERRORS
INTENTIONAL ERRORS
FIVE TYPES OF
DEFECT OCCURRENCES
• 100% INSPECTION:
• Uses inexpensive Poka-Yoke devices to inspect automatically
for errors or defective operating conditions. (Limit switch).
Defect
Error (small cycle)
Conventional Defect
Management Cycle
Check (large cycle)
Action and 3. Shingo wants to
discourage these
feedback or make shorter.
Check
Action and
feedback
Techniques
• Design for Manufacturability
• “Poka-Yoke” System Devices
ERROR PROOFING
Techniques:
• Design For Manufacturability
(DFM)
Technique that Results in Designs that Cannot
be Incorrectly Manufactured or Assembled.
This Technique can also be used to “Simplify”
the Design and therefore reduce it’s cost.
DESIGN STAGE - BEST OPPORTUNITY TO
IMPACT QUALITY & COST
CHANCES FOR
QUALITY & COST COST TO
IMPROVEMENTS IMPLEMENT
COST
Techniques (Continued)
• “Poka-Yoke” System*
Set-Up Devices or Inspection Techniques that
Assure that Set-Up is Done Correctly; i.e. Produces
100% Good Parts from the First Piece on
“Zero Quality Control: Source Inspection and the Poka-Yoke System” - Shigeo
Shingo; 1986
ERROR PROOFING TECHNIQUES
ERROR PROOFING THE PROCESS
• Automatically
Up Up
Stops Process
• Provides Visual
Down Down
Height of Nut
& Audio Control
Nut
Product
Effective Error Proofing
techniques can reduce or
eliminate our dependence
on operator knowledge and
vigilance, therefore
reducing the number of
defects we send to our
customers!!
Levels of Error Proofing
* 100% inspection for containment of a defect should be implemented only as a temporary fix, as it, too, is subject
to operator vigilance.
BASIC FUNCTIONS OF A
POKA-YOKE SYSTEM
• SHUTDOWN
• CONTROL
• WARNING
DETECTION DEVICES FOR
POKA-YOKE SYSTEMS
LIMIT SWITCHES
MICRO SWITCHES
TOUCH SWITCHES
DIFFERENTIAL
TRANSFORMERS
TRIMETRONS
LIQUID LEVEL RELAYS
NON CONTACT DETECTION DEVICES
PROXIMITY SWITCHES
PHOTOELECTRIC SWITCHES
BEAM SENSORS
FIBER SENSORS
AREA SENSORS
DIMENSION SENSORS
DISPLACEMENT SENSORS
METAL PASSAGE SENSORS
COLOR MARKING SENSORS
DOUBLE-FEED SENSORS
WELDING POSITION SENSORS
TAP SENSORS
FLUID SENSORS
FIVE BEST POKA-YOKE
• Missing Parts
– Forgetting to assemble a part - screws, labels, orifice tubes...
• Misassembled Parts
– Misassembly - loose parts, upside down, not aligned
e.g. - brackets (backwards), seals (not aligned),
screws (loose), labels (upside down), ...
• Incorrect Processing
– Disposing of a part rejected at test to the wrong pile
• Incorrect Parts
– Retrieving and assembling the wrong part from a model mix selection -
seals, labels, brackets, cases...
PROBLEM STATEMENT
LOST
WHAT IS THE ROOT CAUSE????
PROBLEM SOLVING PROCESS
Continuous
Institutionalize Opportunity
Improvement
Prevent Select
5. Evaluate 1. Identify
People
&
Teamwork
4. Implement 2. Analyze
3. Plan
Correct Contain
Identify Error Proofing Opportunities
• PFMEA
IDENTIFY • Quality Data, PR/R, Warranty Data...
• Brainstorm (Questions to Ask, Free Form...)
4. IMPLEMENT IDEAS
COMPLETE BEFORE AND AFTER DOCUMENT
Problem
• CALL SOMEONE
• Packaging
• Design Changes
• Layout Changes
• Approvals from Division
• PAPERWORK
• Write P.M. Process
• Re-Write Process Steps
• Purchase Order
• Revise / Revised Layout
OSBORN’S RULES FOR
BRAINSTORMING
• Criticism Forbidden
• Freewheeling Encouraged
• Quantity (Going for a lot of ideas)
• Combine and Expand - Hitch-hiking