Automotive Documentation Development

Develop Process Flow Listing

Enter Every ‘Major’ Process from Flow Listing into FMEA Form

Develop FMEA(s) Element for Every Process

Check for Customer Requirements.

Give careful consideration to what you consider a ‘Major’ process.

Give careful consideration to defining Control Plan stages:

Prototype

Pre-launch

Production

Use the appropriate RPN numbers and considerations of other appropriate information /data to determine Critical Characteristics.

Develop the Control Plan with Critical characteristics

Develop control mechanisms appropriate for Critical characteristics.

Critical / Special Characteristics

Process FMEA

Process Control Plan

Process Flow Diagram

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This diagram is another way to illustrate several developmental / critical paths of the main documentation requirements.

As we discussed earlier, the APQP and Control Plan manual represents these as different, discrete documents. However, one should look at them as ‘element’ requirements. In the Ford DCP the process control plan ‘element’ is in the same document as the process FMEA ‘element’. None the less, the critical path rules still hold true. For example, in the DCP the control plan ‘part’ cannot be completed until the FMEA ‘part’ is completed.

The Juran Trilogy	The Deming PDCA Cycle	QMS Implementation	FMEA Information	APQP Information
Auditing Information	8-D Problem Solving	Statistics	Error Proofing (Poka Yoke)	Brainstorming
Identifying Waste	Pull Systems	Lead Time Reduction	Planned Maintenance	Quick Setup
Discovering Change	Process Capability - Cp vs. Cpk	Histogram Animation	Process Loop Animation	Taguchi Loss Function
		Fishbone / Cause and Effects Animation

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