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How to Demonstrate Stability and Repeatability in very Short Run Process

B

Brad Gover

Involved In Discussions
#1
#1
Hi all! Its been a while since I last logged in. I am performing a FAI for an aerospace company. The company is requiring us to demonstrate process stability and repeatability per AS9102. Problem is we are only producing 5 molded plastic parts per the P.O. We ran a small lot back in 2003 on a different molding machine which is no longer with the company. The mold was in shabby shape so it was reworked too. very little run data was taken outside of the FAI performed then. Stability and repeatability was not a requirement back then. I don't have any run data from the 2003 run and I would seriously doubt using any due to the situation described above. So the question I have is given such a short run of parts to fill the customer demand and no historical data regarding the average and standard deviation, could I just come up with a PPM or Yield value? I know that might not answer the stability requirement. Any thoughts on how I could document at least something other than an FAI?
Thanks,
Brad:thanx:
 
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Bev D

Bev D

Heretical Statistician
Staff member
Super Moderator
#4
#4
hey Brad :bigwave:

the best thing to do is ask your Customer's SQE. with only 5 parts there is no 'statistical' analysis that will mean anything. 100% inspection is the only thing that will tell you what the 'lot' of 5 parts is doing. typically in Aerospace, the customer requires 100% inspection if the stability and capability of the process can't be established. this is where you are.
 
Steve Prevette

Steve Prevette

Deming Disciple
Staff member
Super Moderator
#5
#5
You could at least plot the time sequence of the five items and see if they are continually increasing or decreasing which may be a warning sign.

Are the raw materials and the process cheap enough that you could make 25 of them and see if they are stable and toss 20 of them away?
 
Bev D

Bev D

Heretical Statistician
Staff member
Super Moderator
#6
#6
But why? if you are making only a few parts and they meet spec why does 'stability' or trending matter?
 
B

Brad Gover

Involved In Discussions
#9
#9
You all are so very helpful. I do appriciate the suggustions. I think going back to the SQE with explination of lack of enough data to make any predictions is best. The reliance on the FAI is really the only concrete glimpse into our process.
Thanks for the help!:agree1:
 
B

Brad Gover

Involved In Discussions
#10
#10
Thanks for the help. I think with the FAI and measuring the rest for the critical features is about as good as it will get.
Thanks!
 
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