FMEA and Control Plans for Transactional Processes

B
#1
I have been asked by my boss to help prepare FMEAs and Control Plans for some transactional processes that have been giving us fits.

Flow charts exist for each process. And the FMEA is no problem. I do, however, need some thoughts about the Control Plans.

I was thinking about asking for key inputs and key outputs at each process step, along with a list of associated CTQs - data like you would find on a SIPOC. I would wrap up with a reaction plan.

Does this sound like a good approach?

Thanks
 
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Jim Wynne

Staff member
Admin
#2
ben said:
I have been asked by my boss to help prepare FMEAs and Control Plans for some transactional processes that have been giving us fits.
ben said:
I was thinking about asking for key inputs and key outputs at each process step, along with a list of associated CTQs - data like you would find on a SIPOC. I would wrap up with a reaction plan.
A good idea would be to back slowly away from the buzzwords and explain what it is you're trying to do.
 

Jim Wynne

Staff member
Admin
#4
ben said:
I apologize for bothering you.

Will look elsewhere for assistance.
In fairness, please look at your original question again. What specifically are you talking about when you refer to a "transactional process"? I can guess, but it would be better if you offered more specifics about what you want to know. I have enough experience with FMEA that I feel confident that I could help you. I think I know what's meant by "SIPOC" (it's what was called simply the "I-P-O cycle" back before someone decided to rename it and sell it as something new and exciting) but I get this shaky feeling and my eyes glaze over when the SS buzzing starts. I'd really like to help, but you have to give me a chance.
 

Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#5
:topic:
ben said:
I apologize for bothering you.

Will look elsewhere for assistance.
Ben - I apologise for the misunderstanding. Misunderstandings happen from time to time here as they do in EVERY forum I have ever visited - And sometimes people have had a bad day and answer abruptly. The best I can tell you - And everyone for that matter - Is to try to have some patience with others and not to take offense when someone posts something that can be taken several ways. Nothing here should be taken personally.

I think the forums as a whole are evidence that people are helping others the best they can and while misunderstandings arise from time to time, usually people do get replies to their questions.

You've been around for a long time ad I'd hate to see you go.
 
B
#6
FMEA/Control Plan

Marc - I am the one who should apologize. I was looking for an easy way out instead of hitting the books and doing the reseach on my own.

Thank you for your kindness.

Ben
 

Jim Wynne

Staff member
Admin
#7
ben said:
Marc - I am the one who should apologize. I was looking for an easy way out instead of hitting the books and doing the reseach on my own.

Thank you for your kindness.

Ben
My initial response was abrupt, but no offense was intended. Sometimes the easy way is the best way, and you might just find a better way by asking here, but then again...
 

Wes Bucey

Quite Involved in Discussions
#8
ben said:
Marc - I am the one who should apologize. I was looking for an easy way out instead of hitting the books and doing the reseach on my own.

Thank you for your kindness.

Ben
OK. Now that that's settled. Since you're close to my age, Ben, I propose we have a foot race or a wresting match to determine who sits next to Quality goddess when we have lunch at the Quality Expo in Rosemont later this month. Winner, of course, has to console the loser by paying for lunch! Marc - you are too young to get into this!

Back to the issue of Control Plans: Are you able to do any in-process inspection to catch nonconformances BEFORE additional work is performed on a piece (or pieces) that is already worthless? I find that helps a lot in saving waste, regardless of the statistical methodology I may use. In a big operation like yours, catching glitches BEFORE final assembly of a machine has to be worth something. By CTQ (Critical to Quality?), I suppose you are talking about what automotive guys call "critical characteristics" - flagged with special symbols on the engineering drawings (usually matters of fit or function) which should be covered by SPC (Statistical Process Control) to assure the manufacturing processes are in control. Many of us here in the Cove deal with that sort of thing on a daily basis. This can be a no sweat thread if we all keep our cool (pun intended.)

Can you describe the transactional process(es) in question for an old fogey like me so I can stop talking in generalities and focus in on your problem?
 
B

Bill Ryan - 2007

#9
I'll just chime in by noting a concern of mine. As I've said before - a well performed PFMEA will virtually write the Control Plan for you. Shouldn't you be addressing the key inputs, outputs, CQTs, etc. in the PFMEA? It just sounds (to me) like you're doing this excersize "in reverse". The Control Plan should be the easier document to prepare.

JMHO
 

Jim Wynne

Staff member
Admin
#10
Bill Ryan said:
a well performed PFMEA will virtually write the Control Plan for you.
Agreed, but "well-performed" is the key. The control plan should considered PFMEA output.

Bill Ryan said:
The Control Plan should be the easier document to prepare.
Agreed again, but it's not in most cases because in most cases what's produced is an inspection plan. "Process Control Plan" is a three-word phrase, and too often the emphasis is placed on the last two words rather than the first two. Most of the control plans I see--and I see a lot of them--are egregiously lacking in details about process controls. If process controls aren't discussed in the PFMEA, they won't find their way to the control plan. The whole thing needs to be about A) how to control the process, B) how to verify that the process is in control and C) what to do if something bad happens.
 
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