introduction_to_poka_yoke 防错技术培训和案例

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1、Poka-yokeandJidoka:ContinuousimprovementtoZeroQualityControlIntroductiontoPokaYoke>QualityandHumanError“Toerrishuman…”…AlexanderPopeHumanbeingsmakemistakes,humanbeingssometimesforget.Ifyourelyonahumanbeingtoproducequalityproductandnotmakeamistakeornotforgetsometimes…..Thenyoureallydonotcaretomak

2、eaqualityproduct.ADDRESSQUALITYISSUESTHROUGHTHEPROCESS.>>EvolutionofKey“Lean”Concepts1945:JustInTime1948:Pull:Withrawalbysubsequentprocesses1953:“Supermarket”systems1947:Dualmachinehandling,“L”shapedlayout1953:Workcellsin“U”shapedlayouts1950:Multi(3-4)machinehandling,rectangularor“U”shapedlayout1

3、955:Waterspiderconcept1962:Kanban,companywide,internal1965:Kanban,externalsuppliers1950:Andon,visualcontrolSet-upreduction:internal&external,1ststagesofSMED:1950ShigeoShingobeginsconsultingrelationshipwithToyota:1954InspiredbyToyota“Foolproofing”measures,developsmethodologytoapplytechniquestosour

4、ceinspection:1965SMEDmethodologyformalized:19691950:Foolproofingtechniquesandtheconceptof“autonomation”(Poka-yoke)“ZeroDefects”concept:1975ZeroQualityControlconcept:1977ShigeoShingoToyota&TaichiiOhno=ConceptsrelatedtoPoka-yoke>>ContentsIntroductiontoPoka-yokeandtypesofinspectionsystemsPoka-yokeSy

5、stemsPoka-yokeMethodsCommonMistakeProofingDevicesPoka-yokeexercisesShingoQuiz>>Poka-yokeandJidoka:Simple&ClearPoka-yoke:Poka-yokepreventsdefectsfrombeingmadeJidoka:PreventsdefectsfrombeingpassedontothenextstepintheprocessHumanInspectionHumanInterventionMistakeProofingwithmachineassistToll-gateIns

6、pectionatFinishedGoodsortheendofmainprocessesIn-ProcessInspectionFinalInspectionmaydecrease,operatorsmaydorequiredprocessinspectionsVisualInspection&JidokaThebeginningofautonomation-significantdefectreductionsPoka-yokeEvolutiontowardZeroQualityControl-OperatorTimededicatedtoContinuousImprovement>

7、>ThreeBasicTypesofInspectionTherearethreebasictypesofinspectiontechniquesJudgmentInspectionHuman,visual,possiblymeasuredOnlydiscoversdefectsafterproductionInformativeInspectionStatisticalQualityControl:flowcharts,contr