Strategic Error-Proofing: Achieving Success Every Time with Smarter FMEAs PDF
Preview Strategic Error-Proofing: Achieving Success Every Time with Smarter FMEAs
Strategic Error-Proofing Strategic Error-Proofing Achieving Success Every Time with Smarter FMEAs casev John J. Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business A PRODUCTIVITY PRESS BOOK CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-27 42 © 2009 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works ISBN-13: 978-1-4200-8367-5 (pbk) ISBN-13: 978-1-138-40965-1 (hbk) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. 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CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http:/ /www.taylorandfrancis.com and the CRC Press Web site at http:/ /www.crcpress.com To My Wife Cindy, the greatest person in the world for me. And to our family who makes life complete. Contents Acknowledgments........................................................................................................ix Introduction....................................................................................................................xi PART 1 GETTING STARTED WITH SUCCESS EVERY TIME 1 FMEA, Poke-Yoke, Mistake-Proofing, and Error-Proofing: Sorting Out the Terminology.............................................................................3 2 Success Every Time and Quality Improvement............................................17 PART 2 THE CRITICAL PHASES OF SUCCESS EVERY TIME 3 Strategic Monitoring of the Critical Elements..............................................27 4 Phase I of the Success Every Time Method: Part Level............................35 5 Phase II of the Success Every Time Method: Set-up Level.......................53 6 Phase III of the Success Every Time Method: Parameter Level..............61 PART 3 PERFECTING AND MONITORING YOUR ERROR-PROOFING DEVICES 7 Designing Parts That Are Device Compatible.............................................71 8 Investing in Your Devices..................................................................................75 9 Creating Great Devices, Placing Them, and Verifying Their Success......95 PART 4 SUCCESS EVERY TIME AS A CORPORATE-WIDE STRATEGY 10 The Strategy Behind Success Every Time...................................................107 11 Putting It All Together................................................... 117 Selected Readings......................................................................................................129 About the Author.........................................................................................................131 Index..............................................................................................................................133 Acknowledgments I am so very thankful to all of the people who have helped me become a person who wants to pursue better ways and help other people grow. I also spend my days thankful for our son Tim, our daughter Amy, plus our daughter-in-law Erin, and our favorite dude Noah and favorite dudette Kate. My greatest teachers were my Mom and Dad. You’ll never know the positive impact you have made on all of us (Kathy, Jim, and JoAnn). Thanks also to Marilyn, Jerry, Lisa, and Jon. While writing this book, I was so very lucky to exchange ideas with a number of people, especially Scott Garberding for his vision and common sense. I also benefited greatly from Mark Wrobbel, a true quality profes- sional who constantly looked to find solid methods to make the world of production a better place. During the development of the concepts, I had the pleasure of talk- ing to quite a number of people in the Quality Assurance and Audit Team, Roger Ruggiero, Gene Aldrich, Jeff Bobcean, Gregg Neale, Kim Fleming, Jim Lenhardt, Jim Hare, Kurt Vogler, D’Anna Keeble, Ping Zhang, Anna Cierpial, Jeff Gordon, Todd Anderson, Dave Hartz, Frank Macco, Damon Davie, Kelly Corrin, Ann Miller, Javier Zarazua, Andy Ly, John Lacks, Ken Simpson, and Leslie Michael. The exchange of ideas and the pursuit of the highest standard, like we frequently said, “Ha, ha, ha, this is great, let’s kick it up another notch—Bool-yah!” We must always be pursuing a better way. In addition, a few people said words or made suggestions that stimu- lated a better idea. Greg Deveson had a great way to describe the pursuit of the simplest method, using a term “I want to drive creativity before we spend capital.” I also want to acknowledge Russell Williams and Chris Estock as two people who helped me and others find means to make the process simple and complete. I also want to thank Tere Stouffer for her tireless editing and revising of the book plus Michael Sinocchi for having the confidence in me to pull the book together.
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