Control Plan & PFMEA Review Procedure?

[GunLake]

How often do you guys review your control plans / PFMEA's?

I was recently hit on a customer audit for not having a procedure for reviewing these. I don't believe this is an ISO standard, But does anyone have a procedure for this? How do you go about reviewing/tracking your control plans/PFMEAS, and How often?

I was able to convince them to give us a point (They were scoring each question on a scale of 1-3) back for having it a part of our annual management review meeting, (We do weekly meetings, and an annual one).

But they didn't like the fact we only review them once per year, Which isn't true. I do review them myself often but the fact we do not have a procedure, As well as they were looking for something tracking when & how often we review each one.

Just looking for some examples while I write this procedure, I know It going to be a pain to convince anyone other than me to review them more than annually. Currently We review them during Print Rev changes as well, But again it's a hit or miss if its just me reviewing them or a team effort.

Other than one other thing, I scored really well, Which is a relief considering this was my first customer audit.

Thanks,
GunLake

 

[Ron Rompen]

To the best of my knowledge (don't have the standard on my desk to verify) there is no requirement for a written procedure for your review method. We do annual CP reviews which includes the Process Flow and PFMEA review, on as many different parts/processes as we can manage. Usually it is 3-4 parts per year for each of our engineers. A documented schedule is created and maintained (that way you have evidence for your management review).
I would STRONGLY urge you, when you develop the schedule, don't be TOO ambitious. Select your parts to be audited based on criteria that you develop - we use customer complaint history, scrap rate, and internal deviations to determine our initial target parts, but you may find something more appropriate for your processes.

 

[Brood27]

We just had our IATF audit last week. (automotive stamping plant) I was also hit with a minor for not having a procedure for reviewing Control Plans.

 

[Jim Wynne]

We just had our IATF audit last week. (automotive stamping plant) I was also hit with a minor for not having a procedure for reviewing Control Plans.

What requirement in the standard was cited for not being fulfilled?

 

[Brood27]

What requirement in the standard was cited for not being fulfilled?

8.5.1.1 Control Plan

The organization shall review control plans, and update as required, for any of the following:

f) the organization determines it has shipped nonconforming product to the customer;
g) when any change occurs affecting product, manufacturing process, measurement, logistics, supply sources, production volume changes, or risk analysis (FMEA) (see Annex A);
h) after a customer complaint and the implementation of the associated corrective action, when applicable;
i) at a set frequency based on risk analysis.

 

[Jim Wynne]

8.5.1.1 Control Plan

The organization shall review control plans, and update as required, for any of the following:

f) the organization determines it has shipped nonconforming product to the customer;
g) when any change occurs affecting product, manufacturing process, measurement, logistics, supply sources, production volume changes, or risk analysis (FMEA) (see Annex A);
h) after a customer complaint and the implementation of the associated corrective action, when applicable;
i) at a set frequency based on risk analysis.

Can you demonstrate that those things are done?

 

[Brood27]

No I can’t, but I’ll be able to before next year’s audit.

 

[AMIT BALLAL]

There is no requirement to have a documented procedure for reviewing control plans. What was the objective evidence verified?

 

[Brood27]

There is no requirement to have a documented procedure for reviewing control plans. What was the objective evidence

Actually, I misspoke. Our minor wasn’t for the fact that we didn’t have a procedure. It was because we weren’t reviewing CP at a set frequency based on rpn. Our solution was to write a procedure that states when CPs must be reviewed. Sorry for the confusion.