Family / Generic type of FMEA & Control Plan and Symbols

[sinned]

Althought TS manual has mentioned the possibility of using family / generic type of FMEA and control plan, there are still some other requirements that have to be complied with which does not encourage the use of family PCP.
For example, if i have a family of similar products with different special characteristics symbols and customer requirements, (eg. some products have the total length as special char. while some others products have only the ID as special char.) Required by TS manual, i have to put those symbols on the PFMEA/PCP. Should i put all different symbols for every product no. onto the one family type PFMEA/PCP ? If so, how can i show which symbol applies to which product no. and not the others ?
Another situation that make family type doc difficult is when there is just one product of a family needed to have changes in RPN marking or additional control consideration after, say, a customer complaint. In such case, we usually are forced to create separate docs for that particular part no.

Can you share your experience ?

 

[Zbigniew Huber]

Re. various symbols of special characteristics the solution I used is to create a separate document with own symbols of critical characteristic [CC] significant characteristic [SC] and others [-] and then cross-reference symbols of customers. Then my symbols [CC] or [SC] were used in FMEA, Control Plans and Work Instructions.

TS169494 allows to do it. See. 7.3.2.3:
"...
identify process control documents including drawings, FMEAs, control plans, and operator instructions with the customer's special characteristic symbol or the organization?s equivalent symbol or notation to include those process steps that affect special characteristics.
..."

Re. various requirements in generic FMEA - I suggest to add extra column for filtering purposes. In the column title you can add part number name and then in following rows add "1" or "0" to filter out rows that need to be included or excluded.

 

[Golfman25]

My question is whether it is a true "family" if the critical characteristics are not the same.

How you handle would depend a lot on what you do. I certainly could see you adding a notation that the cc applies only to a specific part no.

 

[sinned]

I considered them as "family" of products bases on the their similarity in configuration, similar raw material, almost the same production processes, and nearly identical process control methods.
The fact is, different product design engineer of different application came to different conclusions when they determine critical characteristics. In some applications, only the OD is important; in other applications, both OD and thickness is important. Some engineer think that none of the dimension is critical; yet other think only the chamfer is a CC, or their end customer think so.
When the number of family members I'm talking is over 50 or even 100 part nos., indicating one by one in a PFMEA or PCP is tedious and prone to error during revision. Is breaking down the docs the only way to go ?