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Our products are Security Cabinets - FMEA & Control Plan Quality Planning help

T

tusmobil

#1
Hello all,

I can see that here are many experienced people, so i would be more than pleased with your help.

First i would like to describe our product and current control.

Our products are
security cabinets. Our proces go from laser cutting to bending, sub -assembling and final assembly. This all parts are welded together.

Our currently control inspection is that we checked every final assembly. We have 6 workers for that. And also this workers are checking the sub - assemblies.

It has never happened that some final assembly was good. So we spending our time for repairs. So that mean that our processes arent capable.
I would like to gradually come to auto - control of workers. That everyone is responsible for wath he is doing.

We have already done the Process Flow chart. And now is the time for FMEA and Control Plan.
I have some question about FMEA and Control Plan. For example:
1. BENDING:
we have about 50 pieces which must be bended for each product.
We have 30 diferent products.
So, when we are making FMEA and analyzing bending:
must we analyzed every piece individual? Or can we just under column Potential Failure Mode say Wrong dimension and wrong angularity? Must we exactly specified which dimension are potential failure? And then prescribe control chart for that dimensions?

2. Sub - assemblies:
Worker get about 20 pieces and he must welded together this pieces. What is your expirience how to control that? That worker him self must measured critical dimension and then record them into special form?

And finaly, if we have RPN higher then 100 we must take recommended action. But what is the value of RPN for puting the potential failure mode into Control Plan?

Im looking forward for your help!
 
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CarolX

Super Moderator
Super Moderator
#2
Hi tusmobil - maybe I can help a little.

Our currently control inspection is that we checked every final assembly. We have 6 workers for that. And also this workers are checking the sub - assemblies.

It has never happened that some final assembly was good. So we spending our time for repairs. So that mean that our processes arent capable.
I would like to gradually come to auto - control of workers. That everyone is responsible for wath he is doing.
First, without knowing how many parts you make, I would say you have too many people "checking" parts. I think you know this and a FMEA is a good tool to begin to identify how you can improve your process.


1. BENDING:
we have about 50 pieces which must be bended for each product.
We have 30 diferent products.
So, when we are making FMEA and analyzing bending:
must we analyzed every piece individual? Or can we just under column Potential Failure Mode say Wrong dimension and wrong angularity? Must we exactly specified which dimension are potential failure? And then prescribe control chart for that dimensions?
I would begin with the generalizations you have laid out. Identify those features that give you the most difficulty at the assembly process. For example, your angles - if you are bending to 90 degrees and your angles are drifting more than 1/2 degree, this can cause serious fit issues at assembly.

2. Sub - assemblies:
Worker get about 20 pieces and he must welded together this pieces. What is your expirience how to control that? That worker him self must measured critical dimension and then record them into special form?
Fixtures and half shears (also called shear perfs) with mating holes. Find ways to eliminate errors - remember, what can go wrong will go wrong. If you can minimize the potential for errors, you can eliminate the need for measurements. Also look at homemade gages for some of the important assembly features. Easy enough to make with a laser.


Hope this helps a bit.
 
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