Shaun
I work for a die casting plant and have limited exposure to injection molding but I do understand your tools don't wear as much/quickly as ours do and I also understand that many of the issues with plastic parts deals with the visuals. I also have no idea how long a production run is for the part you have presented nor the TPM or Operator procedures you employ.
That being said, here goes:
My main "issue" (were I your customer
) would be concerning the Detection values of "1" for everything (
PFMEA). This would imply to me that you were
incapable of sending me a nonconforming part. Typically, a Dectection value of "1" means you have Poka-Yokes in place, yet I don't see mention of them anywhere in these documents. According to your Control Plan, you use a caliper on only two dimensions and rely on Visual Inspection for the remainder of part features. Your frequencies are set at "First/Last shot" with some visuals hourly. Understanding that visual inspection is only 85% effective (at best) and highly subjective, most "guidelines" I have seen published would put the Detection value at, no better than, a "6" (with more than one layer of 100% visual inspection).
Regarding the Control Plan, I don't see any "Process Characteristics" being monitored other than "Die Setup". For example, in the PFMEA the Causes for a sink are shown as "Incorrect Holding Pressure" and "Incorrect Holding Time". I would expect to see some sort of monitoring of these two process parameters rather than relying on visual inspection of the part to tell me there is an issue with the process.
Please understand, these are just my comments and they reflect my experiences and what I expect out of
our PFMEAs and Control Plans. It's very easy to sit back and criticize another's work. I tend to get a little "passionate" with PFMEAs because I have seen the benefits of the discipline when "properly" performed.
Have a great one
Bill