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1、,A Strategy for Performance Excellence,Mistake Proofing the Doing is controlled so it cannot be wrong 100% of the time!,May include: Switches that detect miss-fed parts Pins that prevent miss-feeding Warning lights Sound signals,39,ZDQ/Check and Do/Point of Origin Inspection,Point of Origin Inspecti
2、on,Check for optimum process conditions before processing is done and errors can be made. Instant feedback. Corrections made before defects occur.,40,100% Audit Checks,Point of Origin Inspection on every piece. The second of the 4 basic elements of ZDQ. Differs from SQC inspection: Does not rely on
3、sampling Prevents defects Does not assume defects will statistically occur,100% Audit checks everything on the line!,Zero Defects,41,Quick Feedback,Error correction as soon as possible The third of the 4 basic elements of ZDQ. Differs from traditional inspection approaches that: Correct problems aft
4、er the process Address the problem when errors are already defects In some cases never identify an error has occurred,ZDQ sends the operator a signal and alarms the person that an error has happened! ZDQ Inspections = Immediate Feedback,42,Introduction Defects efforts do not have to result in a 100%
5、 improvement immediately.,44,Introduction Defects does not depend on an operator or assembler. Has a high capability of achieving zero defects. Machine stops when an irregularity is detected.,“There must have been an error detected; the machine shut down by itself!”,51,Warning System,Sometimes an au
6、tomatic shut off system is not an option. A warning or alarm system can be used to get an operators attention. Below left is an example of an alarm system using dials, lights and sounds to bring attention to the problem. Color coding is also an effective non automatic option.,BEEP!,BEEP!,BEEP!,“Im g
7、lad the alarm went off, now Im not making defects!”,52,Methods for Using Poka-yoke,Poka-yoke systems consist of three primary methods: 1. Contact 2. Counting 3. Motion-Sequence Each method can be used in a control system or a warning system. Each method uses a different process prevention approach f
8、or dealing with irregularities.,53,Contact Method,A contact method functions by detecting whether a sensing device makes contact with a part or object within the process.,Missing cylinder;piston fully extended alarm sounds,Contact Method using limit switches identifies missing cylinder.,An example o
9、f a physical contact method is limit switches that are pressed when cylinders are driven into a piston. The switches are connected to pistons that hold the part in place. In this example, a cylinder is missing and the part is not released to the next process.,Cannot proceed to next step.,Cylinder pr
10、esent,54,Physical Contact Devices,Limit Switches,Toggle Switches,55,Energy Contact Devices,Photoelectric switches can be used with objects that are translucent or transparent depending upon the need. Transmission method: two units, one to transmit light, the other to receive. Reflecting method:PE se
11、nsor responds to light reflected from object to detect presence.,Light,Transmitter,Receiver,Object,If object breaks the transmission, the machine is signaled to shut down.,56,Contact Device,An example of a contact device using a limit switch. In this case the switch makes contact with a metal barb s
12、ensing its presence. If no contact is made the process will shut down.,57,Contact Methods,Do not have to be high tech! Passive devices are sometimes the best method. These can be as simple as guide pins or blocks that do not allow parts to be seated in the wrong position prior to processing Take adv
13、antage of parts designed with an uneven shape! A work piece with a hole a bump or an uneven end is a perfect candidate for a passive jig. This method signals to the operator right away that the part is not in proper position.,58,Counting Method,Used when a fixed number of operations are required wit
14、hin a process, or when a product has a fixed number of parts that are attached to it. A sensor counts the number of times a part is used or a process is completed and releases the part only when the right count is reached.,In the example to the right a limit switch is used to detect and count when t
15、he required amount of holes are drilled. The buzzer sounds alerting the operator that the appropriate amount of steps have been taken in the process.,59,Counting Method,Another approach is to count the number of parts or components required to complete an operation in advance. If operators finds par
16、ts leftover using this method, they will know that something has been omitted from the process.,“I have an extra part. I must have omitted a step!”,60,Motion-Sequence Method,The third poka-yoke method uses sensors to determine if a motion or a step in a process has occurred. If the step has not occurred or has occurred out of sequence, the the sensor signals a timer or other device to stop the machine and signal the operator.,This method uses sensors
