The real Link between a PFMEA (Process FMEA) and the Control Plan

Helmut Jilling

Auditor / Consultant
#11
Re: The real Link between a PFMEA and the Control Plan

Is it fair to say that the Process Failure Mode on the PFMEA is the Control Characteristic on the Control Plan?

If so does every process failure need to be addressed in the control plan?


Lastly does anyone have an excel form that would automatically tranfer PFMEA information over to the Control Plan to begin that process?


Thanks in advance,

jakes

1. The control plan should define all characterisitics which you intend to control. If there are characterisitics which you are not controlling, they do not have to be listed.

2. If it is a significant characteristic, or SC, it must be controlled.

3. Powerway makes a very robust database module which handles linking these documents automatically. If you chnage one, it chnages the other. I am not a fan of Powerway in general, but am told this module is quite good.
 
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B

Bill Ryan - 2007

#12
Re: The real Link between a PFMEA and the Control Plan

Is it fair to say that the Process Failure Mode on the PFMEA is the Control Characteristic on the Control Plan?

If so does every process failure need to be addressed in the control plan?


Lastly does anyone have an excel form that would automatically tranfer PFMEA information over to the Control Plan to begin that process?


Thanks in advance,

jakes
Welcome to the Cove :bigwave:

You've gotten some pretty good responses so far - so now I'll give you my :2cents:

I "normally" have Failure Modes on the PFMEA as part characteristics and Failure Causes as process characteristics. Thus, the transfer to the Control Plan is quite simple - Failure Modes are listed in the Product Characteristic column and Failure Causes are listed in the Process Characteristic column. I came to use this methodology due to the "best" software I have come across (I've checked quite a few out. Sorry Wes, but the Powerway module was one of the first I ruled out). It also will allow a process failure to be a Failure Mode (if you desire to do so). The software is distributed by Harpco. This software will "force" you to address each "process failure" (mode or cause) listed on the PFMEA in the Control Plan. As I have said before, I will not go back to a spreadsheet based system as there are too many "opportunities" for errors (unless, of course, I have to :rolleyes:). This software also "automatically tranfer PFMEA information over to the Control Plan".

Does that "muddy the waters" a bit more for you? (I actually hope it helps you out somewhat)

I have no association with Harpco other than being a user of their software.
 
S

S.Karthik

#13
Re: The real Link between a PFMEA and the Control Plan

Hello,

I was looking for the same topic since yesterday.
We had a customer audit and they shattered our PFMEA and Control plan methodology followed and downgraded the marks.
The main negative point by auditor was our Control plan addressed the same failure mode in PFMEA and it is not addresing the process steps for that failure mode.
Refer attached our example

:thanks:
 

Attachments

Stijloor

Staff member
Super Moderator
#14
Re: The real Link between a PFMEA and the Control Plan

Hello,

I was looking for the same topic since yesterday.
We had a customer audit and they shattered our PFMEA and Control plan methodology followed and downgraded the marks.
The main negative point by auditor was our Control plan addressed the same failure mode in PFMEA and it is not addresing the process steps for that failure mode.
Refer attached our example

:thanks:
Would you be willing/able to attach your PFMEA? Without a complete PFMEA and a Control Plan it would be difficult to provide suggestions. If not possible, we certainly understand the proprietary nature of these documents.

Stijloor.
 

Jim Wynne

Staff member
Admin
#15
Re: The real Link between a PFMEA and the Control Plan

Hello,

I was looking for the same topic since yesterday.
We had a customer audit and they shattered our PFMEA and Control plan methodology followed and downgraded the marks.
The main negative point by auditor was our Control plan addressed the same failure mode in PFMEA and it is not addresing the process steps for that failure mode.
Refer attached our example

:thanks:
The problems seem to be more in your control plan than in the PFMEA. You've copied the potential failure causes from the PFMEA into the Process Characteristics column on the control plan, and current process controls from the PFMEA into the Specification/Tolerance column on the control plan. While this is not the place for a comprehensive PFMEA/PCP tutorial, the link between the two documents is pretty simple--what you show in the PFMEA as "current process controls" should be reflected as controls in the PCP. Also, you should be differentiating between prevention and detection controls in the PFMEA. If you don't have copies of the AIAG APQP and FMEA manuals, you should get them. If you do a search of the Cove, you'll also find lots of information and examples.
 
A

Alex Kobzar

#16
Re: The real Link between a PFMEA and the Control Plan

Hello,
...our Control plan addressed the same failure mode in PFMEA and it is not addresing the process steps for that failure mode.
Why do you have failure modes listed in FC and CP?!: )

I believe that
- FC shall list process steps / material flow,
- PFMEA shall list potential nonconformities anticipated at each of the stages (which are listed in the FC) and controls excercised to prevent, detect and correct the noncomformities,
- CP shall list only the controls, responibilities and frequencies for each of the the controls (which are listed in the CP).
 
S

S.Karthik

#17
Re: The real Link between a PFMEA and the Control Plan

Hello,
Thanks for all the quick responses.
Here again I attached a detailed example of our's for Stiljoor

Thanks for the input to read AIAG Manual - Jim
Can you show a direct link in the cove for these examples?

I have to review and make one to get the approval and implement for the whole list.

:(:confused:
S.K
 

Attachments

Jim Wynne

Staff member
Admin
#18
Re: The real Link between a PFMEA and the Control Plan

Hello,
Thanks for all the quick responses.
Here again I attached a detailed example of our's for Stiljoor

Thanks for the input to read AIAG Manual - Jim
Can you show a direct link in the cove for these examples?

I have to review and make one to get the approval and implement for the whole list.

:(:confused:
S.K
Go to the top of this page and click on "Post Attachment List." From the ensuing page you can search for PFMEAs and control plans in post attachments.
 
C

caikaiguang

#19
Re: The real Link between a PFMEA and the Control Plan

Hello Thank everybody for the help you offer ,this is the first time i come here and this is the only one site where i can find the pFMEA and CP reference for plastic mould in English version.
 
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