Lots of products - need CP's

Shaun Daly

Involved In Discussions
#1
Greetings. I have a question for you folks, though I think I know what the answer will be.......

My company has over 500 individual injection moulded products we supply.

Some can be grouped into classes, but a lot are specific (extra brass inserts etc).

Would a TS assessor expect us to create backdated documentation (APQP) for all these parts?

Or could we go the "new products only route" + create documentation for any revised products as they occur?
 
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B

Bill Ryan - 2007

#2
I can only tell you our experience.

"Pre-TS" we were QS registered. Our auditor expected PFDs, PFMEAs, and Control Plans for every automotive part. Under QS we had a "grace period" to get that accomplished, in other words, we could have the "top 25" done by the next audit and go forward that way. It worked out OK and we now have all the documentation in place for roughly 400+ parts.

My understanding is that TS expects it to be in place yesterday. Obviously that can't happen unless you have the intention of going back and doing it "the right way" so you have "useful" documents.

I would suggest a call to your registrar and ask for their interpretation/expectation.

Bill
 
#3
Shaun asks;
"Would a TS assessor expect us to create backdated documentation (APQP) for all these parts?"

Not backdated documentation, but revised/update documentation. During the your periodic review you woild be expected to update your documentation to comply with TS2 requirements.

Note: product realization, in and of itself, requires APQP, plus add-ins. All documentation will be required to be updated to TS2 at some point in the lifecycle of the product.
 
J

Jan T

#4
CP's for plating

As a contract electoplate shop we handle strickly customer supplied product. Do we need to generate APQP documentation for each of customer part number or can we create generic docs for each plating process ie zinc, zinc & chromate, silver, zinc-nickel, copper etc.? We are ISO 9000 certified but are going to TS 16949. so this is a major jump for us. Any help now and again will be greatly appreciated. :bigwave:
 

Shaun Daly

Involved In Discussions
#5
If you have many products which follow the same process I believe you can have a generic Process Flowplan, FMEA & Control Plan.

Where the process differs then you have to go product specific.

Thats the impression I have from reading TS & comments here.
 
#6
Shaun,
The product realization process itself must be customer specific, but Yes, you can have generic documents. The problem IMO, is trying to satisfy more than one customer. For example, customer requirements must be include on FC's CP's & PFMEA's. I know, from previous experience with molded products, that DCX, Ford & GM have different inspection requirements and require different methods for SPC. Also [email protected] requirements are different.
 
T

tomvehoski

#7
Jan,

For the chrome plater I am working with now we created generic control plans, FMEAs and process flows for the most complicated process. For each part we modify from the base document and add the customer specific information (part number, rev level, etc.) We keep the control plans pretty vague on purpose - they don't want to give away their secrets to plating where the customer can give it to another shop that will save them a few cents per part. Process paramaters are kept in separate work instructions which are confiential and referenced by the control plan.

Tom
 

Shaun Daly

Involved In Discussions
#8
>The product realization process itself must be customer specific, >but Yes, you can have generic documents. The problem IMO, is >trying to satisfy more than one customer. For example, >customer requirements must be include on FC's CP's & PFMEA's. >I know, from previous experience with molded products, that >DCX, Ford & GM have different inspection requirements and >require different methods for SPC. Also [email protected] requirements >are different

Good point. Fortunately my company only has 2 main customers & we are all part of the same group.
 
J

Jan T

#9
Control Plans

Thanks to all for your imput. Tom, I will keep in mind your imput on control plans.

Thanks again, I will probably have more questions on other issues later.:bigwave:
 
M

MsHeeler

#10
We have CPs and FMEAs on 9 items that are identical. We got one the way that we wanted it and just changed the part number and revision level, and saved it as a new name.

It worked really well. We have only had to make one change, and it was really easy.
 
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