Is the first piece inspection method supposed to be in the Control Plan?

P

Pudge

#1
Hello,
I am currently in the process of my first Control Plan by myself, I have assisted in a few, but now I am on my own. My question, Is the first piece inspection method supposed to be in the Control Plan?
 
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The Taz!

Quite Involved in Discussions
#2
Pudge said:
My question, Is the first piece inspection method supposed to be in the Control Plan?
Welcome!

I see no reason why it should not be. . . if that is a NORMAL part of your process control techniques or verification, it is absolutely valid to include it. It would a part of setup process verification as I see it. . . of course. . . all you can guarantee if the part is acceptable is that you can ship it. . .subsequent process controls take over in production.
 
B

Bill Ryan - 2007

#3
Welcome, Pudge :bigwave:

I agree with Taz. You're Control Plan should address all the controls you have in place - both Product and Process. We typically have a "First/Last piece" check and then have ""X" times per shift" checks for the die cast operation. Our "First/Last piece" checks include ALL the "per shift" checks. It's just a blurb in the "Sample Size/Frequency column" on the CP.

Good Luck and let us know if you've got any other questions.
 
D

Diana Cadwalader

#4
First Piece inspection in CP

I would have to concur with everyone else -- Your inspection criteria should all be listed in the CP. Particularly if it is being carried from the FMEA. In my experience, the harder part of drafting the CP is in defining the reaction plan. Most CPs that I have seen say "stop and adjust" or "MRR product" - - this is not fulfilling the intent of the CP, which is to instruct the operator as to what action to take to correct the process. Good luck to you.
 

sowmya

Involved - Posts
#5
Diana is very correct. The most harder part is filling the reaction plan. During our audit we have faced the same issue.

I think you can include all the inspection processes (in process, first piece, final etc.,) and set up approvals in the CP.
 
W

wallyqc

#7
First pc.

My first piece inspection work instruction says "inspect 5 parts to all inspection items on the control plan."

wallyqc
 
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Wes Bucey

Quite Involved in Discussions
#9
Please, can you help me understand what you mean by "first piece"?

It seems obvious from the context of the posts so far that we are not talking about "First Article Inspection" which in my experience means checking EVERY dimension and attribute of a part made on the exact production machinery which will be used to continue producing the part. Technically, the First Article is usually not the very first piece, but, in fact, the first piece once the machinery is tweaked, but before actual production is authorized.

In a Control Plan, in my further experience, producers generally include the following steps:
  • First Article Inspection (often redundantly approved by a customer before production can begin if it is a custom part. FAI may be performed under laboratory conditions. The First Article is almost always tagged and reserved for future reference.)
  • an inspection plan to take consecutive samples of the production run at predetermined intervals. (in process) These samples are often only inspected for critical characteristics. Almost always, these inspections are performed by the operators at the machine or by inspectors coming to the machine. (Critical characteristics may be crucial fit or function ones or they may be "process critical" ones which flag when a tool may need to be changed because of wear.)
  • a plan to use the readings from the inspections in statistical analysis (SPC, Cpk, etc.)
In ten years in a high tech machining environment, I never heard the term "first piece" except as shorthand for First Article Inspection.
 

sowmya

Involved - Posts
#10
Good point!. Normally this conflict occurs in my company always. Ours is manual (80%) and Machine(20%) company.

So we have three terms ( I don't know whether it is followed everywhere, but we are following like)
First piece approval - The very first piece of the production ( Manual ) is approved - Obviously we cannot predict all the pieces will be correct. But atleast wrong interpretation or wrong understanding by the operator can be avoided.

Set up approval - For machine dependent processes, the setting of the machines and the output from the machine is verified

First article - As you said, when we ship the samples to customers we call it as first article.

Expecting more arguements / views from everyone

Sowmya
 
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