When is control plan required? Remanufacturing and Repackaging Company

M

Mike Smith

#1
I have a problem and I am not sure what to do about it. Here it goes. We are a remanufacturing company. No problem. We have control plans and FMEA`s for every different type of part. Here is the problem. We have started a new product line. We are making kits for sale to the aftermarket, which involves acquiring injectors, harnesses, gaskets etc. All we do is get the kit together, package it according to customer requirements, reflash the turbo charger and send it to the customer. I have told the engineering department that this requires a control plan and a FMEA since we are doing value added work to the kit. He seems to think a control plan and FMEA are not required since we are only repackaging (he says). Who is right? Can anyone clear this up for me or point me to a place that states when control plans or required?
 
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B

Bill Ryan - 2007

#2
If I understand correctly, you're process is full of potential Failure Modes. As examples - What if you miss a component in the kit, put an incorrect component in the kit, package the kit incorrectly, incorrectly "flash the turbo charger"(?). If you have Potential Failure Modes, and since this is asked in an automotive thread, I would think a PFMEA (minimum) would be a requirement. If you have a PFMEA, I would think a Control Plan would be needed to "support" the PFMEA.

Why is you're engineering dept. balking at a pretty fair risk assessment tool (PFMEA) and documenting the manner in which you should be controlling those risks?

Just my :2cents:

Bill
 
S

sbickley

#3
Control Plan?

Can someone tell me exactly what a control plan is and does and maybe link to an example? I'm trying to figure out the benefit of a control plan instead of just doing the FMEA. Please have patience with me on this topic!

Thanks,
 

Howard Atkins

Forum Administrator
Staff member
Admin
#4
Very simply the control plan takes the FMEA and elaborates on the controls.
When you perform a FMEA you say what controls you have on the part/process. You then decide if these are adequate. If they are RPN (low) then you keep them, if they are not RPN (high) you modify something.
The control plan takes the flow of work and shows what you control, how you control it, with what frequency and what sample side. If these controls do not work then there is a reaction plan as to what you should do next.
In effect it is one document which you probably have as checklists, instructions at each station.

The FMEA is the process and the CP is the output
 
B

Bill Ryan - 2007

#5
sbickley said:
Can someone tell me exactly what a control plan is and does and maybe link to an example? I'm trying to figure out the benefit of a control plan instead of just doing the FMEA. Please have patience with me on this topic!

Thanks,
Very basically, a Control Plan takes each Failure Mode and Failure Cause from the PFMEA and documents your methodology for controlling them at each step in your Process Flow. It get into the "nuts & bolts" of how you control your process.

Help a little??

Bill
 
S

sal881vw

#6
Example of control plan

Hello sbickley,
IMHO, the information you have above is already of great help..........I have added an example below
 

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