I am attending a training seminar on the 'core tools' and the instructor stated some organizations are moving to a merged document that include Process Control Plan, PFMEA and Process Flow Diagram all on one sheet. Has anyone out here actually done that yet? Do you have an example?

Flow charts and Control plans I have seen and is a good idea.There is an example here
: Control plans - TS 16949:2002 requires corrective actions to be addressed (http://elsmar.com/Forums/showpost.php?p=95123&postcount=10)

To add the FMEA seems to me to make the document very complicated.
Has the instructor got a copy?

Flow charts and Control plans I have seen and is a good idea.There is an example here
: Control plans - TS 16949:2002 requires corrective actions to be addressed (http://elsmar.com/Forums/showpost.php?p=95123&postcount=10)

To add the FMEA seems to me to make the document very complicated.
Has the instructor got a copy?

Howard makes excellent points! :agree1:

Also keep in mind that the documents mentioned usually have different users. A Control Plan would be used in manufacturing. A PFMEA, for example would be developed and used by manufacturing engineers who use them to develop Control Plans and Work Instructions. In addition, the complexity of the process can play a role as well in how all this information is going to be "packaged" and presented to the users.

Stijloor.

All documents are found combined on the Toyota Production System initiatives deployed at QSB -a Toyota 'captive' safety restraint manufacturer in Canada. It is combined with Process Quality with Colour and I have used this method effectively in precision gear manufacture. The format was approved by Allison Transmission and effectively served as a work instruction as well so was posted at each support and machining center.

If you wish more information or a specific 'live' example, let me know!

I am attending a training seminar on the 'core tools' and the instructor stated some organizations are moving to a merged document that include Process Control Plan, PFMEA and Process Flow Diagram all on one sheet. Has anyone out here actually done that yet? Do you have an example?

I don't know whether they still do or not, but Ford uses (used) something called a "dynamic" control plan that includes PFMEA information. Because the PCP and PFMEA are supposed to follow the same order as the flow diagram, the PFD is superfluous if the PFMEA/Control plan shows the operations in order of execution.

Anyone who would like either a pdf or spreadsheet of a live example, just email me with Subject: TPS -Process Quality with Color Sample.

Email can be found under profile.

Thanks!