Control Plans and Process Flow Diagrams: What is the Difference?

CarolX

Super Moderator
Super Moderator
#11
GREAT BIG THANKS TO ALL

I just wanted to say thanks to everyone that helped me through my first PPAP. I just received a call from my customer and he said it was one of the best PPAP's seen by his people....to which we both chuckled because we both knew this was my first try at it.

I couldn't have done it with out all your help.

Thanks again!!!!!
:bigwave: :bigwave: :bigwave:

CarolX
 
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R

Randy Stewart

#13
Oh No

Look what you started Carol!!! Now they'll expect that type of PPAP all the time!?!?!?!?!?!?
Good Job. I agree with Bill, that must have been one h*** of a PPAP to get a positive response from a customer.:vfunny:
 
J

Jan T

#14
re: Process Flow Charts & FMEAs

Hi to all;
As a plating company we have a computer generated Manufacturing Order which is geared to the customer part number. It tells the operator what the area batch size, material, amperage, amp. hours minutes etc. It also details any special notes and the inspection criteria. The operators & inspectors sign off on the M.O. Along with this M.O. there is a step by step process procedure that details what tank to use, how long it should be in there,troubleshooting guides, and so on.

We also have an overall generic process flowchart
starting at the material coming in the door to shipping to the customer.

Do I now take all that information and make it conform to the prescribed process flowcharts, FMEAs and control plans? :bonk:
 
B

Bill Ryan - 2007

#15
Hi Jan and welcome :bigwave:

The answer - simply - is Yes!!

It sounds as if your "Generic" Flow chart will need little attention. There is no "prescribed" format for a flow chart unless one of your customers has a format they mandate.

The PFMEA will be your "biggest" hurdle but if your company understands it's processes, it is more a matter of understanding the columns in the FMEA document. It's very easy to get wrapped up in the difference between a Failure Mode and a Failure Cause but the rest of the form is fairly easy to complete. I suggest obtaining the AIAG FMEA manual (3rd ed.) if you don't already have one.

The Control Plan(s) merely take the Failure Mode and Failure Cause columns and place them into the "Characteristics - Product|Process" columns. The entire "right side" of the Control Plan is merely listing the specification, how you are monitoring it, and how you react to a nonconformance.

Hope that helps get you started.
Bill
 
R

Randy Stewart

#16
Not much to add

Welcome Jan,
I don't really have much to add, I think Bill has pointed you in the right direction and I agree about the biggest hurdle. What I have experienced is that you really have to keep focus on the developed process while going through a PFMEA. The first few you do can really be frustrating, mainly due to the word "potential". Remember you're dealing with reality not theoretical. I've had people ask about putting in things like the operator is sick! Focus on the process you have and known problems, you can branch from there if needed.:bigwave:
 
L

Link Xue

#17
Re: Control Plans and Process Flow Diagrams

Originally posted by CarolX

A Control Plan provides detail on how each of these steps will be monitored and controled.

Hi all
I have a confusion now. In my poor concept about the control plan, it is only be used on key processes. But according to the thread, the control plan should be used to each step. In this way, does the control plan look a bit like a working instruction?
Please point out my mistake. :D
 
B

Bill Ryan - 2007

#18
Only have a minute - Each step in the process flow needs to be "looked at" in the Control Plan. If you can't produce a nonconformance, there are simply no entries for that step (possibly transport or accumulation/delay steps for example).

While you could take the Control Plan to the "work instruction" level, there are probably some issues your management would have from the proprietary angle, if you send your Control Plans to customers.

Gotta run, but I'll be back :bigwave:

Bill
 
L

Link Xue

#19
Originally posted by Bill Ryan
If you can't produce a nonconformance, there are simply no entries for that step (possibly transport or accumulation/delay steps for example).
Thank you Bill, but still a little confusion with quoted as you saying.
If possible can you send a simple control plan to me for better understanding?

thank you :)
 
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