防误措施
MISTAKE-PROOFING 防误措施
ACE Elements

ACE 内容
ACE Elements
ACE 内容
Benefits of Mistake-Proofing 防误措施的好处
Increase profitability by eliminating inadvertent mistakes
消除无谓的错误可增加利润率

Increase productivity by reducing wasted time
减少浪费的时间可提高生产力

Improve customer satisfaction and quality by eliminating escapes
消除逃脱可提高客户满意度和质量

Increase reliability by continuously improving products, services or processes
不断改进产品、服务或程序可提高信誉
Mistakes vs. Defects 错误vs 过失
They are not the same thing! Mistakes Cause Defects.
他们是不同的！ 错误导致过失
Most Common Mistakes 最常见的错误
Misunderstanding requirements
误解了要求

Skipping a process step or tasks
漏掉了一个工作步骤

Performing process steps incorrectly or in the wrong order
未正确地或以错误地顺序执行程序步骤

Contamination
污染
Leaving out a part or a piece of information
漏掉了一个零件或一条信息

Adjustment and measurement mistakes
调节和测量错误

Timing mistakes
定时错误

Using the wrong part, tool or information
使用了错误的零件、工具或信息
Mistake-Proofing 防误措施
Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly.
防误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。


It removes uncertainty from the situations where errors are most likely to occur, such as:
它去除了最可能发生错误的情形中的不确定性，如：
Repetitive tasks 重复性的任务
Complex instructions 复杂的说明书
Calculations / Adjustments 计算/调节
Look-alike parts 相似的零件

Why do we do Mistake Proofing? 为什么我们要采用防误措施？
To prevent turnbacks and customer escapes from recurring, since the cost to fix a problem increases rapidly the later it is found:
为防止缺陷和客户逃脱情况再次发生，因为问题发现得越晚所花的费用就会迅速增加：
2 Approaches to Mistake Proofing 预防错误的2个途径
Mistake-Proof 防误措施
the Design 设计

Redesign the product
重新设计产品
Eliminate the mistake condition
消除犯错误的条件
Redesign for symmetry or asymmetry
重新进行对称或不对称设计
Change the materials
改变材料
Change component type, characteristics or supplier
改变组件的类型、特征或供应商
Mistake-Proof 防误措施
the Process 加工

Change or add tooling
改变或增添工具

Change process steps
改变加工步骤

Add use of checklists, templates or gages
增加使用清单、模板或测量仪

Implement control charts
执行控制图表

Example of Mistake-Proofing the Design 防误措施范例 设计
Process Description: Making a pot of coffee
程序描述：泡一壶咖啡
Example of Mistake-Proofing the Design 防误措施范例 设计
Process Description: Making a pot of coffee
程序描述：泡一壶咖啡
Example of Mistake-Proofing the Design 防误措施范例 设计
Process Description: A label is pasted into a recess in a molded chassis
程序描述：将标签贴在底盘的凹槽内
Example of Mistake-Proofing the Design 防误措施范例 设计
Process Description: Install slides into a slide projector
程序描述：将幻灯片装入幻灯机中
Example of Mistake-Proofing the Design 防误措施范例 设计
Process Description: Torquing a number of bolts recessed deep in a cavity.
程序描述：将大量螺栓拧进空腔深处的凹槽内
Mistake-Proofing isn’t Words! 防误措施不是文字！
Mistake-Proofing is a way of using wisdom and ingenuity to create devices that ensure a task is always done correctly.
防误措施是指运用智慧和独创性发展出一个能确保任务总是能正确完成的设备的方法。
Most Common Types of Mistake-Proof Devices 最常见的防误设备
Guide pins or interference pins
向导图钉或干涉图钉

Templates
模板

Part kits using shadowboxing
使用能防止错误的零件包

Limit switches
限制阀

Counters
计算器

Alarms
闹钟

Weights and measures
称重秤和测量仪

Checklists
清单

Control charts
控制图表
Mistake-Proofing Process Changes 防误码程序的改变

Improve the process! 改进程序！
Simplify 简单化
Reduce steps, parts, forms, data on forms, number of process steps, etc.
减少步骤、零件、表格、表格上的数据、加工步骤的数量等。
Consolidate/Co-Locate 巩固/共用
Bring operations closer together, reduce work-in-process (WIP)
使操作变得更紧凑，减少过程工作（WIP）
Standardize 标准化
Make the process visual 使程序可见
Move responsibility and authority down in the organization
将责任和权利下放给组织
Creating Mistake Proofing 创建防误措施
Try-Storming (vs. Brainstorming)
尝试风暴 （对头脑风暴）

Involve the right people
让合适的人参与

Walk the process and get the facts
检验程序并获得事实

Don’t just sit and think about solutions... TRY THEM!
不要只是坐在那儿想解决问题的方法…
去尝试！
Test Mistake Proofing with the “Nasty Test” 用“恶心的试验”来验证防误措施
The “Nasty Test” (vs. the “Solution”)
“恶心的试验” （对“解决方法”）
When you think you’ve got the best solution… TRY TO MAKE IT FAIL!!!
当你认为你已找到最佳解决方法时… 试着去让它失败
Involve all users
让所有使用者参与
Mistake-proof devices must be 100% effective at dealing with a particular mistake
在处理特殊错误时防误设备必须100%有效
If not, they will be ignored
如果不能，就应放弃
Ensure the mistake-proof doesn’t create another problem
确保防误措施不会引起其它问题
When do you do Mistake-Proofing 何时采取防误措施
Formally, as part of the QCPC/MFA Process
形式上的，作为QCPC/MFA程序中一部分
Three Levels of Mistake-Proofing 防误措施的三个等级
There are 3 Levels of Mistake-Proofing based on effectiveness and speed:
防误措施有三个基于有效性和速度的等级：
Level III: Detection
等级三：发现

Level II: Alert
等级二：警告

Level I: Prevention
等级一：防止
Three Levels of Mistake-Proofing 防误措施的三个等级
Level III, Detect: Allows you to detect your Mistake after it has occurred. (1 point)
等级三，发现：在已经发生之后发现错误
Checklists 清单
Computer beeps 电脑提醒
Manually activated Spell Check 手工拼写检查
Level II, Alert: Alerts you as the Mistake is happening. (2 points)
等级二，警告：当错误正在发生时提醒你
Sensors, alarms, control charts 传感器、闹钟、控制图表
Counters 计算器
Automatic Spell Check 自动拼写检查
Level I, Prevent: Prevents you from making the Mistake. (3 points)
等级三，防止：防止你犯错误
Eliminating the mistake condition (changing the design)
消除犯错条件
Automation 自动控制
Spelling “Auto-corrector” 拼写“自动更正器”
Mistake Proofing Qualifying Level Items 防误措施合格水平内容
The following 2 items are required to achieve the ACE Qualifying level for Mistake Proofing
要取得ACE的防误措施合格资格必须完成以下两项内容
Summary 总结
Mistakes are not inevitable.
错误不是不可避免的。
A Mistake-Proof is a creative device that prevents a mistake from happening. It should be:
防误措施是一项有创造性的设备能防止错误发生。它应该是：
Simple 简单的
Inexpensive 不昂贵的
Reliable at preventing defects or giving prompt feedback.
在防止错误或给出提示反馈时可靠的。
Mistake Proofing is critical to process improvement.
防误措施对程序改进很重要。
Necessary to achieve QCPC turnback reduction goals.
对达到QCPC减少缺陷的目标是必要的
Mistake-Proofing enhances our work environment by making it easier to do our jobs well.
防误措施通过使我们的工作更容易作好来改善我们的工作环境

防误措施