Defect awareness training vander bend bh rev 02
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Poka-Yoke Training given to Vander-Bend Manufacturing product builders
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Defect awareness training vander bend bh rev 02
- 1. Developed by: Baqar Hasan 03/14/13 Rev. 01
- 2. 2 Objectives On completion of this course, you will be able to: • Identify the defects • Identify places in your work area where you can help prevent defects • Test ( 5 questions, 80% passing marks)
- 3. 3 Almost all defects are caused by human errors. There are at least ten kinds of human error. • Forgetfulness: Sometimes we forget things when we are not concentrating. Safeguards: Alerting operator in advance or checking at regular intervals • Errors due to misunderstanding: Sometimes we make mistakes when we jump to the wrong conclusion before we are familiar with the situation. Safeguards: Training, checking in advance, standardizing work procedures
- 4. 4 • Errors in identification: Sometimes we misjudge a situation because we view it too quickly or are too far away from it to see it clearly. Safeguards: Training, attentiveness, vigilance • Errors made by amateurs: Sometimes we make mistakes through lack of experience Safeguards: Skill building, work standardization • Willful errors: Sometimes errors occur when we decide that we can ignore rules under certain circumstances. Safeguards: Basic education and experience
- 5. 5 • Inadvertent errors: Sometimes we are absentminded and make mistakes without knowing how they happened. Safeguards: Attentiveness, discipline, work standardization • Errors due to slowness: Sometimes we make mistakes when our actions are slowed down by delays in judgment. Safeguards: Skill building, work standardization • Errors due to lack of standards: Some errors occur when there are no suitable work instructions or standards. Safeguards: Safeguards: Skill building, work standardization
- 6. 6 • Surprise Errors: Errors sometimes occur when equipment runs differently than expected. When working on hot or rush jobs Safeguards: TPM, work standardization • Intentional Errors: Some people make mistakes deliberately. Crimes and sabotage are examples. Safeguards: Poka-yoke methods
- 7. 7 2. What are the Sources of Defects There are various types of defects. In order of importance these are: • Omitted Processing • Processing Errors • Errors setting up work pieces • Missing parts • Wrong parts • Processing wrong work piece • Misoperation • Adjustment error • Equipment not set up properly • Tools and jigs improperly prepared
- 8. 8 Exercise What kind of error? DIESEL What kind of error? What kind of error?
- 9. 9 • PEM Nuts -DOCO missing a stand-off • Extra Hole • Missing documentation -Certs, FAIRs • Machining Work Steps • Threads - center thread rivet missing • Label • Card Guides • Simulator GPU bracket missing • Hash marks • Cutout • Panel lock • Screw/Spring on RAC Bracket Missing Parts, Process Steps, Documentation
- 10. 10 Parts Mix-up • Wrong type of standoffs used • Wrong type of Screws • Wrong labels used
- 11. 11 Incorrectly Worked Upon Parts • Spot weld diameter • Spot weld pattern • Hole not chamfered • Wrong artwork • Uniform paint thickness not achieved • Cutout for connector in wrong position • Forming defect – cover wider on one side • Not machined completely • Wrong hole position on HD Bracket • Bad base console-flange formed 0.03 off dimension
- 12. 12 • Armrest-metal showing through foam • Card cage misaligned • Card guides not fully seated • Cover painted on wrong side • Column cover tab came off • Electrical VSC has bad harness • Electrical-G889, VSC has no video • Cover formed with large taper • Rivet installed on wrong location • Simulator Bracket missing hardware • Contamination-parts not cleaned prior to shipment to customer • White spots on arm rest POD Wrong Assembly
- 13. 13 Wrong orientation • Rivet installed on wrong location • Form angle error • Wrong hole position on HD bracket • Holes not aligned properly for riveting • PEM nut wrong size/orientation
- 14. 14 Five most common causes of defects 1. Inappropriate procedures or standards 2. Excessive variability during operations 3. Damaged or excessively variable materials 4. Worn machine parts 5. Simple human mistakes (least predictable of the five)
- 15. 15 Defect Awareness Test 310307-02 316221-01 15001600-F 314988-06 313742-02 Rac2, Rac1 PN. Defective Y/N Defect Name: Employee #: Extra Hole Forming Error -off by thousands Wrong sized PEM Wrong distance from the edge Holes not aligned when SBP board is installed PEM Nuts in wrong holes Defects
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- I. Welcome I welcome you to Poka-Yoke class. II. Brief Introduction III. Workshop Duration 1-1/2 hours. IV. Certification One of the courses for Yellow Belt certification. V. Teams Some Poka-Yoke teams were formed in the Fab. VI. Story When Ford started rolling out cars from their Assembly Plant in Dearborn Michigan in 1906 their slogan was, “paint them blue and push them through”. People were buying one car for use and one for the spare parts. After almost a century Toyota has established a benchmark in the auto industry by exceeding six sigma quality levels. They have achieved these levels by using poka-yoke techniques in their factories. We are here today because our defects rates are high. We have a long way to go towards Six Sigma or Zero Defects type of manufacturing. There are companies and industries in the world who have already achieved Zero Defects and are talking quality in terms of ppm (parts per million) or ppb (parts per billion). Motorola and Toyota are two such companies. When Motorola manufactures one million cell phones there are only 3.4 defects (six sigma). VII. Participant Guide & Tour We took a group of employees on a tour of NUMMI Plant which is a collaboration between Toyota and GM. It helped tour attendees see Lean Manufacturing in Action. Your Participant Guide includes an article on NUMMI.. Poka-Yoke is an integral part of Lean Manufacturing. Reference Books The books which we have used to prepare these material are on the table. You can have a look at these books and note the author’s and publisher’s name if you want to order these books . DO YOU HAVE ANY QUESTIONS OR CONCERN
- These are the objectives of the class but the main objective of this workshop is to involve You folks in the process of eliminating defects from production.
- EXPLAIN The first step in going towards “zero defects” is to understand that why we are making mistakes. We need to look at the causes of both the errors and the defects. We need to find permanent fixes in order to eliminate recurring problems. What is needed to prevent these errors from happening? One way is to make design changes. Another way is to change our behaviors and get better trained in the operations we perform. How can we prevent errors? By modifying processes or change designs to eliminate the chance of introducing defects. This may include the use of jigs, guide pins, and limit switches Actually modifying the product to eliminate the chance of improper assembly. BRAINSTORMING Causal Connections Between Defects and Human Errors ( Refer to page 14 of Poka-Yoke book). Use this exercise if time permits. On the flip chart write causes of error in the column and the causes of defects in the row and ask the audience to create a relationship between the above. Check for strongly connected or connects.