The test for many SQE's auditing a supplier process is "can I walk the process using the documents provided? - Flow Diagram,
PFMEA, Control Plan?"
Some OEM's ask "Are the documents linked (Key'd) ?"
These are supeanable documents in US courts that can be used to determine DUE CARE and assign liability in the event of a catastrophic failure. REF: Ford/Firestone issue some years ago.
Much of the information and methodologies has changed over the years some for the good and some due to lack of understanding not so good.
Most of the OEM's are delighted to see...
Every Step of the Process (anywhere the material/product goes)
Every Step of the process that is also an operation (anything that changes the configuration of the material/product).
And that the Flow,
FMEA, Control Plan are linked.
The reason that they are happy to see that is... Once they sign off on the PPAP they are assuming a certain amount of liability and they feel more comfortable that you really have an understanding of your process.
Typically you might see...
Step 1 Rec Raw Material
Step 2 Move Material
Step 3 Store Material
Step 4 Move Material
Step 5 (Operation 10) Mold Material
Step 6 Move Material
and so on.
The PFMEA would capture the same Steps and Operations.
The Control Plan in many cases would be the same sequences but may not cover everything and may look more like...
Step 1 Rec Raw Material
Step 5 (Operation 10) Mold Raw Material
And so on.
Very much like another poster indicated.
If your material routing is different than your Quality Documents you may have an error in one or the other - I would imagine that someone may have asked for the routing at some point in time, however I suspect that this is rare.
If your documents do not match what is on the floor you are increasing your companies potential liability, which many agree is a primary purpose.
TR