Poka Yoke
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Poka-Yoke Introduction (PL) - Co to jest: Metoda eliminująca możliwość popełnienia błędu - Zastosowanie: Tam gdzie błędy są nagminne - Gdzie: Najczęściej tam gdzie detale podobne są kształtem i rozmiarem
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Poka Yoke
- 2. Poka Yoke Czy błędów można uniknąć? Każdy błąd można wyeliminować!… przecież błędy są nie do uniknięcia…
- 3. Kupiłem jedną sztukę i się zepsuła… Nie jestem zadowolony! Cały dzień zajęłoby nam sprawdzanie wszystkich naszych produktów. Najlepszym sposobem jest kontrola statystyczna. Mamy poziom błędów tylko 0,1% Poka Yoke
- 4. • Zapomnienie • Niezrozumienie • Błędną identyfikację • Brak doświadczenia • Zaniedbanie • Przypadek • Powolność • Brak standardu • Niezamierzone • Zamierzone Rodzaje błędów Błędy popełniamy przez:
- 5. Błędy popełniane przez: Przykład Wskazówki ZAPOMNIENIE Dróżnik zapomniał opuścić szlaban Wcześniejsze powiadamianie, przypominanie lub kontrola Rodzaje błędów
- 6. Błędy popełniane przez: Przykład Wskazówki NIEZROZUMIENIE W samochodzie z automatyczną skrzynią naciskamy hamulec myśląc, że to sprzęgło Szkolenie, standardowe procedury, wcześniejsze sprawdzenie Rodzaje błędów
- 7. Błędy popełniane przez: Przykład Wskazówki BŁĘDNĄ IDENTYFIKACJĘ Banknot 1$ wydaje nam się 100$ Szkolenie, zwrócenie większej uwagi Rodzaje błędów
- 8. Błędy popełniane przez: Przykład Wskazówki BRAK DOŚWIADCZENIA Nowy pracownik nie zna wszystkich czynności Szkolenie, praca według standardów Rodzaje błędów
- 9. Błędy popełniane przez: Przykład Wskazówki ZANIEDBANIE Przechodzimy przez ulicę na czerwonym świetle, ponieważ nie nadjeżdża żaden samochód Podstawowa edukacja i doświadczenie Rodzaje błędów
- 10. Błędy popełniane przez: Przykład Wskazówki PRZYPADEK Ktoś zamyślony próbował przejść przez ulicę nie zważając na czerwone światło Zwrócenie większej uwagi, dyscyplina, standaryzacja Rodzaje błędów
- 11. Błędy popełniane przez: Przykład Wskazówki POWOLNOŚĆ Kursant na kursie prawa jazdy reaguje wolniej, gdy ma nacisnąć hamulec Szkolenie, standaryzacja Rodzaje błędów
- 12. Błędy popełniane przez: Przykład Wskazówki BRAK STANDARDU Operator sam decyduje o przeprowadzeniu pomiaru Szkolenie, standaryzacja, instrukcje Rodzaje błędów
- 13. Błędy: Przykład Wskazówki NIEZAMIERZONE Urządzenie zaczęło pracować wadliwie bez ostrzeżenia Utrzymanie ruchu, standaryzacja Rodzaje błędów
- 14. Błędy: Przykład Wskazówki ZAMIERZONE Przestępstwa, sabotaż Edukacja, dyscyplina Rodzaje błędów
- 15. Nie stać nas na utratę wizerunku. Będziemy kontrolowali 100% produkcji Poka Yoke
- 16. Poka Yoke • Co to jest? Metoda eliminująca możliwość popełnienia błędu • Zastosowanie Tam gdzie błędy są nagminne • Gdzie? Najczęściej tam gdzie detale podobne są kształtem i rozmiarem.
- 17. Poka Yoke – przykłady rozwiązań • Różnego rozmiaru kołki prowadnicze • Sygnały alarmowe i fotokomórki • Przełączniki kontrolne • Liczniki • Listy kontrolne
- 18. Wskazówki Poka Yoke • IDENTYFIKACJA PRZDMIOTÓW PO ICH CECHACH CHARAKTERYSTYCZNYCH - Waga (ustal standard dotyczący ciężaru, użyj wagi lub innego przyrządu do pomiaru ciężkości) - Wymiar (ustal standard dotyczący szerokości, średnicy, itp. i zastosuj ograniczniki) - Kształt (ustal standard dotyczący kąta nachylenia, wypukłości, pozycji otworów, itp. i zastosuj ograniczniki)
- 19. Wskazówki Poka Yoke • WYKRYWANIE ODCHYLEŃ OD STANDARDOWEJ PROCEDURY - Sekwencja procesu (dalsze operacje nie mogą być wykonane jeżeli operator lub maszyna nie pracuje zgodnie ze standardem)
- 20. Wskazówki Poka Yoke • WYKRYWANIE ODCHYLEŃ PRZY ZASTOSOWANIU USTALONEJ WARTOŚCI - Liczniki, skanery (sygnał informuje jeżeli numer nie zgadza się z ustalonym) - Metoda nieparzystej części (kiedy w komplecie jest odliczona ilość części, dostajemy informację jeżeli zostanie jedna część) - Wykrywanie warunków krytycznych (jeżeli wartość różni się od ustalonej, operacja nie może być wykonana)
- 21. Strategia „ZERO DEFEKTÓW” 1. Wbuduj jakość w proces 2. Wszystkie błędy i defekty mogą być wyeliminowane 3. Przestań wykonywać źle, zacznij dobrze – natychmiast 4. Nie wymyślaj wymówek, pomyśl jak wykonać prawidłowo 5. 60% sukcesu wystarcza – wdróż pomysł od razu 6. Błędy można wyeliminować gdy ludzie pracują razem 7. Co 10 głów to nie jedna 8. Poszukaj przyczyny źródłowej (stosując np. 5 x dlaczego)
- 22. Co robić ? KAIZEN 5 S KANBAN S.M.E.D. T.P.M. Lean Manufacturing Six Sigma T.O.C. S.P.C. FMEA Just in Time Value Stream Problem Solving Groupworking M.T.M. ? ? ? ? ? ? ? ? ? ?
- 23. Rola diagnozy z filozofii Lean Manufacturing „…ci którzy obserwują rzeczywistość uważnie podejmują lepsze decyzje…”