Automotive Sampling Plans. HELP! Working on an Automotive process control plan

[Manix]

HI all,

Can anyone point me in the correct direction(s)?

I am working on an Automotive process control plan and need some advise about sampling rates.

I know next to nothing about the standards used and need to implement some plans for checking a number of product attributes and measureable data.

We will be using GP12 for a period so this may effect the sampling plans.

Can anyone just give me some guidance on where to look, I know there is not enoght info here to provide firm assistance!

 

[Helmut Jilling]

HI all,

Can anyone point me in the correct direction(s)?

I am working on an Automotive process control plan and need some advise about sampling rates.

I know next to nothing about the standards used and need to implement some plans for checking a number of product attributes and measureable data.

We will be using GP12 for a period so this may effect the sampling plans.

Can anyone just give me some guidance on where to look, I know there is not enoght info here to provide firm assistance!

If you are under the GM GP12 (GM 1920) Procedure, at a minimum, you will want to make sure you review that Procedure, and your team needs to be familiar with the APQP and Control Plan AIAG manuals. Knowing "next to nothing about the standards used" is not the best approach if you want to meet your customer's expectations. Spending a little time now to review them may save significant cost later if there is an issue. (A "Controlled Shipping" status situation can cost between $25,000 - 100,000 if it were to occur).

 

[Jim Wynne]

HI all,

Can anyone point me in the correct direction(s)?

I am working on an Automotive process control plan and need some advise about sampling rates.

I know next to nothing about the standards used and need to implement some plans for checking a number of product attributes and measureable data.

We will be using GP12 for a period so this may effect the sampling plans.

Can anyone just give me some guidance on where to look, I know there is not enoght info here to provide firm assistance!

As hjilling suggests, if you don't have the documentation for GP12 and APQP, that's where you need to start. Also, do a search of the Cove for sampling plans; you'll find a lot of good information.

 

[Caster]

HI all,

Can anyone point me in the correct direction(s)?

I am working on an Automotive process control plan and need some advise about sampling rates.

I know next to nothing about the standards used and need to implement some plans for checking a number of product attributes and measureable data.

We will be using GP12 for a period so this may effect the sampling plans.

Can anyone just give me some guidance on where to look, I know there is not enoght info here to provide firm assistance!

Hi Manix

Do you need guidance on sampling plans or on control plan inspection frequencies?

On the control plan we typically have 100% checks recorded on a checksheet, 1 part every 2 hours recorded on a computer print out, 3 parts every 2 hours tracked on an SPC chart, and 100% visual with no record.

Why these? In theory the frequency of checks should come from failure data, but I guess most suppliers set it at how many they care to sort if they find a bad one on a check.

If you tell us more, I am sure more specfic examples will be offered up. What kind of parts/process do you have?

Cheers from the Dominion of Canada

 

[bpritts]

Hi, Manix,

The automotive folks do not get into great detail on sampling. For many years, there's been a shift away from statistical sampling toward SPC, process control in general, and lately error-proofing. So you won't see specifications of minimum sample size, etc., very much. (As I recall, Ford does specify minimum sample sizes to determine process capability. Look in the TS16949 Ford Customer Specific Requirements (IAOB.ORG has these)).

What the documents usually say is that you need to achieve statistical capability on key dimensions, and capture enough inspection data to demonstrate ongoing control. (This would imply SPC subgroups of 3-5 consecutive samples from each process stream "every so often". You decide what a logical sampling plan might be.)

This information is included in the PPAP manual, as I recall.

If you don't have statistical control, then 100% inspection is needed.

Whatever you decide to do for the ongoing process, you need to do more for GP12. It is common to do 100% inspection on critical characteristics for the first few days' production for GP12. Understand that this is intended as an
audit of your existing production/inspection plan! The idea is that if your processes are capable and your inspections adequate, the GP12 inspections will prove that you are good!

Best of luck,

Brad