Customer keeps rejecting my Process Control Plan (PCP)

Boubacar

Starting to get Involved
#1
I've attached a process control plan that I have sent to my customer. The customer is not automotive but are using the PCP framework. As I am a relative newbie regarding process control plans, I'm wondering if anyone can take a look and give me recommendations.

Customer's comments:

Some of the statements don't appear in the correct columns.
What is the criteria in the verification of step 7 (tinting and promoting)
What are instruments/gauges verified to calibrated standards (length, level, ultrasound).

I've asked for clarification with them and they sent me a sample PCP but I think that mine generally matches (although difficult because of different processes).

Also, I acknowledge that the PCP is extremely generic, this was on purpose as the customer has alot of custom work that may involved different specs, processes etc.

Any comments would be greatly appreciated.

Thanks
 

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Jim Wynne

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#2
Re: Customer keeps rejecting my PCP

I've attached a process control plan that I have sent to my customer. The customer is not automotive but are using the PCP framework. As I am a relative newbie regarding process control plans, I'm wondering if anyone can take a look and give me recommendations.

Customer's comments:

Some of the statements don't appear in the correct columns.
What is the criteria in the verification of step 7 (tinting and promoting)
What are instruments/gauges verified to calibrated standards (length, level, ultrasound).

I've asked for clarification with them and they sent me a sample PCP but I think that mine generally matches (although difficult because of different processes).

Also, I acknowledge that the PCP is extremely generic, this was on purpose as the customer has alot of custom work that may involved different specs, processes etc.

Any comments would be greatly appreciated.

Thanks
It's hard to tell what the customer is looking for. I understand the comment about step 7; mixing resin isn't an evaluation or measurement technique. How do you determine whether the mix is compliant or not? You should ask the customer for specific examples of things not being in the correct fields, and what they mean with regard to calibration.
 
Z

zancky

#3
Hi Boubacar,
our control plan have the same format but the content is quite different:mg:
I suppose You need a real example, I can confidentially send one but I can only do if You send me a message in my area with Your e-mail address

My customer will not accept Your control plan too
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#4
Customer's comments:

Some of the statements don't appear in the correct columns.
What is the criteria in the verification of step 7 (tinting and promoting)
What are instruments/gages verified to calibrated standards (length, level, ultrasound).

Also, I acknowledge that the PCP is extremely generic, this was on purpose as the customer has a lot of custom work that may involved different specs, processes etc.

Any comments would be greatly appreciated.
I agree with your customer, although as a part of their vendor development, they should sit down with you for a few hours and go through this process with you.

Generically speaking:

1. Most control plans start at the process input, which is raw materials. Some of the previous steps can be addressed elsewhere in the quality system.

2."Move material to storage area" Is this staging of the material prior to mixing? If so, how do you know how much and what material to move? Process and product parameters need to be measurable - either by attribute or variable means. one process parameter may be "Move correct material to staging area". What is the tolerance? "Correct material according to blend sheet" (attribute) What is the size and frequency? every batch, 100%. What is the control method? "Verify bar code or material label to batch sheet" - it tells the operator what material and how much for that batch.
The next item for "Move material to storage area" may be "Move correct quantity of material to staging area". What is the tolerance? "Correct amount of material according to blend sheet +/- 5 lbs" (variable) What is the size and frequency? every batch, 100%. What is the control method? batch sheet - it tells the operator what material and how much for that batch. It may also be using a scale to verify the weights.

3. Mixing Resin: Product Characteristic: may be "Add correct quantity of resin tint". What is the tolerance? "Correct amount of material according to blend sheet +/- 5 lbs" (variable) What is the size and frequency? every batch, 100%. What is the control method? batch sheet - it tells the operator what material and how much for that batch. It may also be using a scale to verify the weights. I would also expect to see Process Characteristics: How long do you mix? Do you add any heat or cool? Is so how much? What RPM do you mix? They can also be generic, directing the operator to the blend sheet for specific info for the product.

I could go on for hours, but I thought this may be a good start for further discussion. :cool:
 
R

Randy Stewart

#5
:agree1:Good job Bob, very understandable. It should help them a lot. Too bad the customer wouldn't take the time to share similar info.
Sounds like you've gone through this a time or two.:applause:
 

Caster

An Early Cover
Trusted Information Resource
#6
3. Mixing Resin: Product Characteristic: may be "Add correct quantity of resin tint". What is the tolerance? "Correct amount of material according to blend sheet +/- 5 lbs" (variable) What is the size and frequency? every batch, 100%. What is the control method? batch sheet - it tells the operator what material and how much for that batch. It may also be using a scale to verify the weights. I would also expect to see Process Characteristics: How long do you mix? Do you add any heat or cool? Is so how much? What RPM do you mix? They can also be generic, directing the operator to the blend sheet for specific info for the product.

I could go on for hours, but I thought this may be a good start for further discussion.


There is a chance that all of this is covered in the statement "Mix resin as indicated resin mix book"

IF (a big IF) the "resin mix book" covers these questions, I could be talked into accepting the CP as is.

Mixing temperature and RPM MAY (a big MAY) be considered company trade secrets and it would not be appropriate to publish them on a CP.

You never know how much or little detail the customer wants, and often you get a new person at the customer who makes you change what the last one asked for.

Unless you are doing CP for your own benefit, the game seems to be keep making the minimum demanded changes requested until they need the parts and have to sign the warrant.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#7


There is a chance that all of this is covered in the statement "Mix resin as indicated resin mix book"

IF (a big IF) the "resin mix book" covers these questions, I could be talked into accepting the CP as is.

Mixing temperature and RPM MAY (a big MAY) be considered company trade secrets and it would not be appropriate to publish them on a CP.
I would still cite them as controlled variable ("take credit for the control"), but leave the specific RPM, etc., in the recipe for confidentiality. I bet they control it - or they will be sucking bubbles out the resin for quite a while if they whip it into a frenzy. Playing the role of a customer, I would want to see what variables the vendor is attempting to control (and how they are attempting to control them), which ones they actually pondered about (effective FMEA process?) - whether they cite the specifics in the control plan or not. I will be able to ponder what failure modes to expect, from experience, if the vendor is not "taking credit" for controlling certain process and product parameters.
 
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