mistake proofing in design

7/25/2019 Mistake Proofing in Design

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Final Draft.ppt Slide: TBD.1 TRW Automotive 2005

Chapter TBD

Mistake Proofing In Design

Chapter ObjectivesTerminology & Quality System Issues

Assembly Concepts & Constraints

Mistake Prooing Metho!s & "valuation


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Common Terminology

#$A%#esign $or Assembly e!uce costs o assembly activities

#$M%#esign $or Manuacture e!uce costs o component & part abrication

'#$MA( )OT* !irect as well asin!irect costs+

Not u!t "redu#tion$ %& #o!t allo#ation'

Mistake Prooing Poka%,oke or "rror Prooing-Making it !iicult

to make errors in assembly or manuacturing

Part O #$M.#$A activities


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Final Draft.ppt Slide: TBD.( TRW Automotive 2005

Mistake Prooing

Process Control That- Prevent a ailure cause rom arising-or

Prevent a cause rom becoming a ailure )revent a defe#t from o##urrin*

De#ouple #au!e and effe#t

e!uce the occurrence o a ailure cause

/Avoi! Ina!vertent "rrors0-Poka ,oke /,okeru Poka01 2ot aime! at '3illul errors(

Mistake Prooing Can )e SigniicantlyAecte! )y Pro!uct #esign #ecisions 2ot just a manuacturing issue


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Final Draft.ppt Slide: TBD.+ TRW Automotive 2005

Starting Point

e4uires Close Cooperation )et3een#esigners5 Pro!uct "ngineers an!Manuacturing & In!ustrial "ngineers Pro!uct engineers & !esigners must un!erstan!

ho3 !esign !ecisions aect operations

A!!em%l& , fa%ri#ation limitation! mu!t %e #on!idereddurin* de!i*n a#tivitie!

Mistake prooing is not just about manuacturingcontrol-but manuacturing control is the goal

A Pro!uct #esign That Cannot )e Pro!uce!eliably Is 2ot A Successul #esign+


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$oun!ation Concepts

#$SS A!!resses e!uction In 6ariation obust "ngineering5 2oise Management5 #$M"A &

#esign 6eriication Activities

Some 6ariation Arises $rom 'Special Causes( 7ne8pecte! things that occur in manuacturing

7sually !ue to human or machine errors

Mistake Prooing Is A #$SS Tool That *elpse!uce Special Cause 6ariation9 Mistake prooing is !riven by manuacturing

consi!erations Fa%ri#ation , A!!em%l&: )eople , -a#ine!

*o3ever5 mistake prooing can be inluence! &

improve! through pro!uct !esign !ecisions


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Final Draft.ppt Slide: TBD./ TRW Automotive 2005

*uman Constraints1 Shingo

*umans 7nlimite! number o

a8es o motion

'Programme!( 4uickly

an! eiciently-but can

orget the 'program(

6ulnerable to harsh

environments: saety is

a signiicant concern

Minimum maintenance

re4uire! on%site ;ack repeatability:

errors are likely

Mechani


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Final Draft.ppt Slide: TBD. TRW Automotive 2005

Ina!vertent "rrors

"rrors in Manuacturing Are Oten #ue to*uman $actors People are not machines

People inherently lack repeatability

Pro!uct !esigns an! process controls thatignore this are likely to pro!uce non%

conorming goo!s in e8cess o si8 sigma

targets on a regular basis

Can ,ou Count => Pieces epeate!ly? 'All men are liable to error( @ ohn ;ocke


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Final Draft.ppt Slide: TBD. TRW Automotive 2005

Billul "rrors

Operator Ignores ules Consciously chooses to not ollo3 proce!ures

an! use a D3ork%aroun!D instea!

7sually #ue To Process #esign $la3s Or

Poor Maintenance Tape! !o3n limit s3itches

Mirrors on photo sensors

Operators rarely !o this or amusement+ Pro!uction 3orkers & supervisors are ju!ge!

on throughput Sift uota! and !ippin* !#edule!


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Slide: TBD.3 TRW Automotive 2005

Important Assumptions

Billul "rrors Bill 2ot Occur This is a management issue+

7pstream Operations & Supply ChainActivities Provi!e Materials that Conorm

To #esign Criteria I previous activities are properly mistake

prooe!5 this 3ill generally be true

I upstream activities are !iicult to mistake

proo5 then mistake prooing may be a!!e!!o3nstream

But it 4ill %e le!! effe#tive


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Final Draft.ppt


Mistake Prooing Is 2ecessary

'it became evi!ent that achieving a CpE

F 3oul! go only part o the 3ay Mistake Prooing the !esign 3oul! also be

re4uire! Mistake Prooing the !esign is an

essential actor in achieving the goal o si8

sigma( Smit6 B. 7888 Spe#trum (093 +(;+

"ven A Great Si8 Sigma #esign May )e

Aecte! )y Manuacturing ealities9


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Pro!uct #evelopmentPerspective

Mistake Prooing Must )e Integrate! IntoBorl!%Class Pro!uct eali


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Final Draft.ppt


6eriication & 6ali!ation

6eriication Proves That A #esignConorms To Customer e4uirements #oes not inclu!e manuacturing assumptions

'#6(

6ali!ation $ollo3s 6eriication Proo o manuacturing easibility

Physical !emonstration using 'inal operating

con!itions(

-anufa#turin* pro#e!! , intended u!e

-i!ta>e proofin* inte*rate! de!i*n , manufa#turin*

i!!ue! in validation

'P6(


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Final Draft.ppt

Slide: TBD.1( TRW Automotive 2005

G#PIM Outline

Integrate #$A Into C6 & #6 Activities Mistake prooing is also critical to Process #esign

)eriperal effe#t on D< %ut #riti#al effe#t on )

mistake proofing in design

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