Control Plan Training
Control Plans
Page 2
Control Plan
Control Plans:
•
•
•
•
•
•
Control the risks identified in the P-FMEA (High RPNs)
A structured approach to control process and product characteristics
Focusses on Customer Requirements
Assure reaction plans are in place in case of out-of-control conditions
Provide a central document for communication of control methods
A Control Plan contains following key information:
 Identification of the control factors
 The specifications and tolerances
 The measurement system
 Sample size and frequency
 The control method
 The reaction plan
• Control Plans are living documents, just like FMEA’s
3
Page 3
Control Plan, Objectives
Objectives of the training:
• To understand the use of a Control Plan
• To learn the steps to develop a Control Plan
• To learn how to link each step in the Control Plan
to the FMEA
4
Page 4
Control Plan, Summary
Control Plan, a systemic way to Control a process:
• Define Characteristics per process step:
• Machines, Devices, Jigs and Tools
• Product, Process and Special characteristics
• Define Methods per process step:
• Process and Product Specifications and Tolerances
• Measurement and Inspection techniques
• Sample size and frequency
• Actions that should be taken in case of
Non Conformities
5
Page 5
Control Plan, Summary
Control Plan, a systemic way to Control a process:
• Verify if defined steps are followed
• Audit the process by Control Plan on a regular
base
• Update the Control Plan consistently
6
Page 6
Benefits Control Plan, Inputs
Control Plan, inputs might include following tools:
•
•
•
•
•
•
•
•
•
•
FMEA
Flow Chart (process sequence)
Lay-out Plan production line
Sequence Of Events
Part Number/ Tooling / Tool List
Assembly Drawing
Specifications/ Dimensions/ Tolerances
CTQ List
Process Map
Historical OMS
7
Page 7
Control Plans, Planning
A build
B build
Pilot
Drawing
Issue part approval form
Tool development
FMEA + control plan
Fit / performance
1.
Purchasing
Source
SQE
QA
Conditional approval
2. HVPT approval
3. Part approval
SQE approval
Quality and capacity confirmation
HVPT process approval
Issue HF PA
requirements
HF proto part
approval
MF and LF
part receipt
HF full part
approval
(OT/OP)
Inspection OK
– NOK send
CAR’s
VCB approval
Page 8
SOP
Control Plans
Prototype
Control Plan Number
Pre-launch
Production
Key Contact/Phone
Date (Original)
Part Number/Latest Change Level
Core Team
Date (Revised)
Part Number / Description
Plant / Supplier Approval Date
Customer Eng.'s Approval / Date (if Required)
Other Approval / Date (if Required)
Customer Quality Approval / Date (if Required)
Plant / Supplier
Part /
Process
Number
1
Supplier Code
Process Name /
Operation Description
Machine Device
Jig. Tools
for Manufacturing
2
3
Characteristics
No.
4
Product
Process
5
Special
Characteristics Product/Process
Class
Specification
tolerance
6
A
B
Operation
Characteristics
7
8
Methods
Evaluation
Measurement
Technique
Page 9
Size Freq.
9
10
C
Methods
Advanced Product Quality Planning (APQP) Reference Manual, QS-9000
Reaction
Plan
Sample
Control
Method
11
12
D
Reaction
Plan
Control Plans
What is being done?
A
Operation
PART/
PROCESS
NUMBER
LTVL010
PROCESS NAME/
OPERATION
DESCRIPTION
8416010, FRAME, 1x
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
1
1. Part/Process Number:
• Usually referenced from the process flow chart, PFMEA or
Tool sheets
2. Process Name/Operation Description:
• Identify the process/operation that best describes the
activity being addressed (e.g. work elements)
• Use verb / noun format
3. Machine, Device, Jig, Tools for Manufacturing:
• Identify the processing equipment required. (e.g..
machine, device, jig power tools, assist arms, conveyors,
etc.)
Page 10
Control Plans
What is Important?
B
Characteristics
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
1
CHARACTERISTICS
NO.
1
PRODUCT
Appearance
PROCESS
Inspect the frame
4. Number:
• Identifies the cross reference number from the applicable
documentation.
5. Product Characteristic:
• Distinguishing features and/or attributes
6. Process Characteristic:
• Characteristics of the process
7. Special Characteristic:
• key processes (e.g. Delta K, QS)
Page 11
SPECIAL
CHAR.
CLASS
Y
Control Plans
Characteristics: Identify Product and Process
characteristics for each Control Plan step
PRODUCT
CHARACTERISTIC
• physical properties of the part
• Identified important customer
characteristics (CTQs and
Delta-K)
Examples: length, width, tensile
strength, torque, weld integrity, color,
alignment, etc.
A description of the state of the
component or vehicle after the
particular operation is completed
Page 12
PROCESS
CHARACTERISTIC
• identify characteristics, which
when controlled, reduce
variation in product
characteristics
Examples: pressure, temperature,
force, feed rate, RPM (torque), etc.
Related to product characteristics
Control Plans
C
Methods
What is the Means for Controlling?
8. Product/Process Specification:
• Specifications/tolerance for a part or process. (eg. may be
obtained from various engineering documents)
9. Evaluation/Measurement Technique:
• Identifies the measurement system being used to measure
product/process characteristics. (eg. gages, fixtures, test
equipment, blocks, go/no go, etc)
10 / 11. Sample Size/Frequency:
• List sample size and frequency to perform evaluation. (eg. size: 4
pieces / frequency: fifth time per shift)
METHODS
PRODUCT/PROCESS
SPECIFICATION/
TOLERANCE
No damage
Page 13
EVALUATION/
MEASUREMENT
TECHNIQUE
Visual Inspection
SAMPLE
SIZE
FREQ.
1
1/Works
hop
CONTROL
METHOD
OMS
REACTION
PLAN
Inform Trainer
Control Plan,
Benefits
Sample size and frequency
• Until a process is Capable (Cpk 1.33), 100% Inspection is required
• If process is Capable, define Sample Size and Frequency reflecting acceptable risk
10-nov-08
9-nov-08
8-nov-08
7-nov-08
6-nov-08
5-nov-08
4-nov-08
Xbar-R Chart of x
1
Mee-1248
Mee-1251
1
2
3
1
Mee-1291
2
2
1
Mee-1256
3
4
5
6
3
1
SPC Chart
20
Sample Range
1
LCL=27.82
2
Sample
Mee-1289
UCL=20.15
15
10
_
R=6.17
5
0
Mee-1257
LCL=0
1
Mee-1258
2
3
4
5
6
Sample
1
4
Mee-1260
OK
35
1
Mee-1255
Total NOK
__
X=39.42
40
Counting Defects
Mee-1253
Mee-1259
45
30
Mee-1250
Mee-1288
UCL=51.01
50
Sample Mean
Mee-1247
3-nov-08
Station:
Install O-ring
C/R into C/C
S/R assy
S/R height
V-coupling assy
Act assy
Lever welding
Lever welding
Act measurement
Engraving
Rev & K-ring check
Weld-assy-act
C/C angle check
V-coupl-lever-act
2-nov-08
1-nov-08
• Use Six Sigma tools and techniques to control the Process
2
3
220
2 1247
450
0
300
0
7
1
2
0
4
350
455
275
400
430
C-Graph of Defects
Page 14
Capability Graph
1
4
Control Plans, Control Method
C
Methods
12. Control Method:
• Brief description of how the operation will be controlled
• When selecting the method of control, focus on:
• process control rather than product control
• prevention rather than detection
• targeting nominal rather than specification limits
Examples:
- Check sheets (weld, quality, tool, - Variation control charts
material, etc)
- Error/mistake proofing
- Preventative tooling maintenance - SPC charts
METHODS
PRODUCT/PROCESS
SPECIFICATION/
TOLERANCE
No damage
Page 15
EVALUATION/
MEASUREMENT
TECHNIQUE
Visual Inspection
SAMPLE
SIZE
FREQ.
1
1/Works
hop
CONTROL
METHOD
OMS
REACTION
PLAN
Inform Trainer
Control Plans, Reaction Plan
D
Reaction Plan
13. Reaction Plan:
• Specifies who to inform to make a decision or what to do when a
process goes out of control
• Written for people closest to the process (e.g. replace a drill)
• Review systemic root cause and update the FMEA
Examples:
- Call supervisor
- 100% Inspection until the process is back in control
- Calibrate equipment
METHODS
PRODUCT/PROCESS
SPECIFICATION/
TOLERANCE
No damage
Page 16
EVALUATION/
MEASUREMENT
TECHNIQUE
Visual Inspection
SAMPLE
SIZE
FREQ.
1
1/Works
hop
CONTROL
METHOD
OMS
REACTION
PLAN
Inform Trainer
Control Plans, Plug Example
Control Plan Number
Key Contact/Phone
Date (Orig.)
Wytse Zijlstra
05/10/2016
Part Number/Latest Change Level
Core Team
Customer Engineering Approval/Date (If Req'd.)
PL30
Wytse Zijlstra, Stephen McLaughlin
Part Name/Description
Supplier/Plant Approval/Date
1
Plug assembly
Supplier Code
Hyster-Yale Group
PART/
PROCESS
NUMBER
N/A
N/A
Other Approval/Date (If Req'd.)
Other Approval/Date (If Req'd.)
H-Y
PROCESS NAME/
OPERATION
DESCRIPTION
PL-10
1010; 1 Plug face
PL-10
1345; 1 Cable Grip.
1060; 2 cable screw s
PL-10
Deliver batch of plugs to station 2
PL-20
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
N/A
CHARACTERISTICS
NO.
PRODUCT
PROCESS
SPECIAL
CHAR.
CLASS
METHODS
PRODUCT/PROCESS
SPECIFICATION/
TOLERANCE
Select 1 plug face w ith
inside facing operator
1
Code: PA320,
White Bar Grip
Rew ireable 13A
Resilient Plug Top
Assembly
Fit 1x Cable Grip using 2
cable screw s. Screw hand
tight
Y
Ensure Cable Grip
screw s go through
back of cable grip
6789; 1 Fuse holder
2
Assembly
Fit fuse holder
Y
PL-20
1011; 1 Live pin
3
Assembly
Fit 1 Live pin
Y
PL-20
1213; 1 Neutral pin w ith black band on
pin
1415; 1 Earth pin
4
Assembly
Fit 1 Neutral pin
Y
Assembly
Fit 1 Earth pin
PL-20
1617; 1 fuse 13 Amp
1616; 1 fuse 5 Amp
5
Assembly
Fit 1 fuse
Check correct location
of the fuse holder
Pin has fuse clamp on
top
Check if black band on
pin
Check if pins are in
correct position
13 Amp fuse
5 Amp for Euro
PL-20
Deliver batch of plugs to station 3
Box
PL-30
2022; 3 screw s to connect w ires
Screw driver
PL-30
Deliver batch of of plugs to station 4
PL-40
1819; Plug Front
PL-40
2013; Wiring diagram
PL-40
Deliver batch of plugs to QA
PL-20
1
Customer Quality Approval/Date (If Req'd.)
15/10/2016
Supplier/Plant
Date (Rev.)
SAMPLE
100%
OMS
Inform Trainer
Hand tight
100%
OMS
Adjust/ re-check
OMS
Inform Trainer
Visual Inspection
100%
OMS
Adjust/ re-check
Visual Inspection
100%
OMS
Adjust/ re-check
Visual Inspection
100%
OMS
Adjust/ re-check
Visual Inspection
100%
OMS
Adjust/ re-check
Visual Inspection
100%
OMS
Adjust/ re-check
OMS
Inform Trainer
OMS
Adjust/ re-check
SIZE
Box
6
Assembly
7
Assembly
8
Assembly
Box
Page 17
Deliver batch of plugs to
station 3
Fit 1 screw to Neutral pin,
Earth pin and Live pin and
tighten hand tight w ith
screw driver
Y
REACTION
PLAN
EVALUATION/
MEASUREMENT
TECHNIQUE
Visual Inspection
FREQ.
CONTROL
METHOD
Y
Ensure all screw s are
nipped tight and unable
to undo by hand
Hand tight
100%
OMS
Inform Trainer
Fit Plug Front
Y
Hand tight
100%
OMS
Adjust/ re-check
Fit w iring diagram
Y
Ensure all screw s are
tight
Ensure text is readable
Visual Inspection
100%
OMS
Adjust/ re-check
OMS
Inform Trainer
Control Plans, Next Steps
Next Steps to H-Y Suppliers:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Know your customers’ expectations - CTQ’s (Critical to Quality
Characteristics)
Have a defined and documented production process (SOE)
Follow 5S Principles
Employ a formal training system
Involve the people on the shop floor
Audit the production process constantly
Manage supplied parts and control supplier performance
Measure/monitor key quality performance indicators
Use an effective Corrective & Preventative Action Process
FMEA and Control Plans are mandatory for PPAP
submission level 3.
Page 18
Control Plans, Next Steps
Page 19
Quality Focus Day Workshop
List of acronyms:
CTQ: Critical To Quality, a characteristic judged to be important to the fit and function of a component or assembly as well
as customer satisfaction
FMEA: Failure Mode and Effect Analysis
ICAM: Interactive Corrective Action Management
OMS: Operational Method Sheet
Off Tool: (Production Tooling) - When a part is said to be “Off Tool” it is required that the part be manufactured using the
exact tooling which will be used for long-term production. This does NOT mean the parts were manufactured from tooling
that is “like” or “similar” to the intended production tooling.
Off Process:(Production Process) – When a part is said to be “Off Process” it is required that the part be manufactured and
tested using the exact process that will be used for long-term production. This does NOT mean the parts were
manufactured using a “like” or “similar” or less than 100% completed process.
P.A.: Part Approval process to determine if part characteristics and specifications are understood and met by the supplier.
PCR: Process Change Request
PFD: Process Flow Diagram
SQM: Supplier Quality Manual
QFD: Quality Function Deployment
QS-9000, PPAP: Product Part Approval Process
QS-9000, APQP: Advanced Project Quality Plan
Page 20