Control Plan - "Latest Change Level" vs. Print Revision Level

D

ddunn

#11
Rather than associating the products to the control plan, associate the control plan to the products. This will make the control plan part of the product BOM the same as any other part in an assembly. Intangible items such as test plans, assembly procedures and control plans are part of the product configuration and can make the product a unique item dependant on the intangibles applied to the product. Review of the intangibles becomes a normal part of the Change Order review for the product.
 
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B

Bill Ryan - 2007

#12
ddunn said:
Rather than associating the products to the control plan, associate the control plan to the products...
I think that's what Mark was alluding to. While I agree with the concept of "family" Control Plans, I have, pretty much, directed us to part specific CPs as too many of my customers expect it that way. By that I mean, they want to see their specific dimensional callouts - not something like "refer to part drawing".

The PFMEA is another story. We have that document associated to the part. For example, in most processes I can think of, a hole is a hole whether it's a mounting, clearance, attachment, etc. hole - the failure modes/causes should be pretty generic to whatever process is used to manufacture the hole.
 
H

heliosgirl

#13
One More Control Plan question

I'm struggling with this Control Plan. The part is pretty much assembled by hand since it is such a low volume part. There are 7 operations including one requiring 24 hrs for a rubber o-ring to set to prevent leaks. How do you try and control operations that are done by hand where there seems to be little control. Also, I've never seen an example of a Process Sheet. Does someone have one I can take a look at? Maybe I could use a Process Sheet instead of trying to write a Control Plan.
 
B

Bill Ryan - 2007

#14
heliosgirl said:
I'm struggling with this Control Plan. The part is pretty much assembled by hand since it is such a low volume part. There are 7 operations including one requiring 24 hrs for a rubber o-ring to set to prevent leaks. How do you try and control operations that are done by hand where there seems to be little control. Also, I've never seen an example of a Process Sheet. Does someone have one I can take a look at? Maybe I could use a Process Sheet instead of trying to write a Control Plan.
Have you performed a PFMEA on the part? A well done PFMEA will "write" your Control Plan for you with regards to the Product and Process Characteristics columns. Then it is just a matter of "filling in the blanks" as to tolerances, frequencies, sample sizes etc. This is an "automotive thread" so I'm guessing you don't have a lot of wiggle room regarding having/not having a Control Plan. It sounds as though you are only doing a Control Plan which, from an auditing standpoint, would suggest disparities between your PFMEA and Control Plan (finding?).

It may seem there is "little control" yet there must be some kind of controls in place or I would expect you would have a pretty dissatisfied customer on your hands (high PPMs). I would start by just documenting what you currently have in place and, if need be, work on the weak areas.
 
A

amr1234

#15
Bill Ryan said:
Have you performed a PFMEA on the part? A well done PFMEA will "write" your Control Plan for you with regards to the Product and Process Characteristics columns. Then it is just a matter of "filling in the blanks" as to tolerances, frequencies, sample sizes etc. This is an "automotive thread" so I'm guessing you don't have a lot of wiggle room regarding having/not having a Control Plan. It sounds as though you are only doing a Control Plan which, from an auditing standpoint, would suggest disparities between your PFMEA and Control Plan (finding?).

It may seem there is "little control" yet there must be some kind of controls in place or I would expect you would have a pretty dissatisfied customer on your hands (high PPMs). I would start by just documenting what you currently have in place and, if need be, work on the weak areas.

This is a little :topic: . Another one of my simple questions.

a. if we add another body to perform a separate inspection process do we need to change the control plan and the process flow diagram to accommodate this addition?

b. the currect control plan groups (assemble, inspect, and pack)

c. the product moves to this station and inspected, then it is moved to the ready to ship area. (all the same department) {assembled (move) inspected (move)packed}

( I think we could issue a quality alert if this is a temporary measure.)

:thanx:
 
B

Bill Ryan - 2007

#16
amr1234 said:
This is a little :topic: . Another one of my simple questions.

a. if we add another body to perform a separate inspection process do we need to change the control plan and the process flow diagram to accommodate this addition?

b. the currect control plan groups (assemble, inspect, and pack)

c. the product moves to this station and inspected, then it is moved to the ready to ship area. (all the same department) {assembled (move) inspected (move)packed}

( I think we could issue a quality alert if this is a temporary measure.)

:thanx:
a) Adding a body to a currently defined inspection step should not need an update (depending.....). Adding a body to the cell to perform a "new" inspection step would, in my methodology, require an update to the Flow Diagram which would require an update to the PFMEA, which would require an update to the Control Plan.
b) Do the Flow Diagram and PFMEA also "group" these? Although I have grouped more than one processing step before, I have "changed my ways" and am not a proponent of it. It hides too many "steps" (transfers, "delays") and could hinder any "Value Stream" improvement activities (as an example).
c) Thanks for the explanation. After Pack, I assume there is a "move" to the dock and some other activities performed there.

What I am "missing" is why you are adding an inspection step (if that's what is happening) without updating the PFMEA (what occurred that this is now a need?).
 
A

amr1234

#17
Bill Ryan said:
a) Adding a body to a currently defined inspection step should not need an update (depending.....). Adding a body to the cell to perform a "new" inspection step would, in my methodology, require an update to the Flow Diagram which would require an update to the PFMEA, which would require an update to the Control Plan.
b) Do the Flow Diagram and PFMEA also "group" these? Although I have grouped more than one processing step before, I have "changed my ways" and am not a proponent of it. It hides too many "steps" (transfers, "delays") and could hinder any "Value Stream" improvement activities (as an example).
c) Thanks for the explanation. After Pack, I assume there is a "move" to the dock and some other activities performed there.

What I am "missing" is why you are adding an inspection step (if that's what is happening) without updating the PFMEA (what occurred that this is now a need?).
The Flow diagram and the PFMEA do not match and do not reflect the same insection as the control plan. I will be writing the Non conformance to reflect this also.

Correct, after pack then the next move is to the dock.

The reason why they added the inspection step was because they had a scare before I arrived.(Several) Poor quality was the result and now they are saying they are just being safe.

Your response reflected my response. :yes:
 
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