Control plan
(Practical Manual)
1.What is the Control Plan
It is one of the most used tools on the floor and is a structured way of following a logical sequence (almost always the process or operations flow is followed) of inspections.
It requires us to review all the characteristics of the product and the process, sample quantity and frequency (how often it must be dimensioned), who is responsible, and most importantly, which registration must be filled out and your reaction plan, we it helps to distinguish which are the “special” characteristics, those that affect the assembly, and those of minor appearance.
2.Who Uses the Control Plan:
Generally it is for the operating personnel and those who are in charge of a production line and when it processes batches ranging from 20 pieces to 10,000 pieces or according to the standard of pieces x production hour.
3.Who Prepares the Control Plan:
The control plan is prepared by a responsible team where personnel from the engineering, quality, production, tools or maintenance departments and plant management must participate.
4.Each time the Control Plan must be filled out:
You must always work on the control plan and it is strictly necessary to always carry it if you want to have quality and an effective culture of quality for customers and operating personnel.
5.Example of Control Plan
FMEA
(Practical manual)
1.What is Amef
It is one of the tools where you can pre-define problems in process and design.
In the Process (P-FMEA) in this particular amef you can find our areas of opportunity to improve our process and it helps us to measure based on a number called "Priority Risk Number" which is the one that tells us if we have to set actions.
To reduce such numbering
2.Who uses the Amef
The entire company must use and carry an Amef from the purchase of raw materials, components, tools, labeling, shipping as well as in the control of the process of any branch of the industry and especially in the Automotive sector, which is one of the most demanding industries that require an Amef
3.Who Makes the Amef:
The Process Amef is prepared and carried out by a responsible team (Multidisciplinary Team) where personnel from all departments of engineering, quality, production, tools or maintenance and plant management must participate and who analyze potential problems to develop the product on the floor and with the existing machinery, as well as the process controls that must be paid special attention to avoid failures with the internal or external client and / or user of our product;
The Design Amef: This is prepared and carried out by the personnel in charge of designing and carrying out the plans and designs as well as verifying the feasibility that the product to be designed can meet all the client's expectations as well as the failures that the design may cause of this product.
4. How often the Amef is used
Forever; The Amef must be updated day by day, since it is a living document and as the processes change, the Amef changes and is updated every day, and the Priority Risk Numbers must be reviewed to establish recommended actions to be re-calculated. the priority number and evaluate the actions taken and see if they worked or not
5.What are the columns that should be carried in an Amef
Column Description
1 Process, Function or Requirement
2 Potential Mode of Failure
3 Potential Effect of Failure
4 Severity
5 Classification
6 Potential Cause
7 Occurrence
8 Current Process Control (Prevention)
9 Current Process Control (Detection)
10 Detection
11 RPN (Priority Number Risk)
12 Recommended Actions
13 Responsible and Date of Completion of Actions
14 Actions Taken
15 Severity (After Recommended Actions)
16 Occurrence (After Recommended Actions)
17 Detection (After Recommended Actions)
18 RPN (After Recommended Actions)
Brief Explanation of Each Column
1. It is where the operation or process is named where you are going to focus the Amef
2. It is where you define which failure mode you identified to prevent and control it
3. It is where you determine what effect the failure would have on the product
4. Severity according to a table (provided by the AIAG) where depending on the failure of the product, a number is determined that goes from 0 to 10
5. Classification: It is when a failure mode is considered a critical or control characteristic and a defined logo is written there or, as in the case of Ford, it is written “SC” (Special Characteristic)
6. It is where the potential Cause of the Failure is determined, or what caused the error in the process
7. Occurrence: According to a table (provided by the AIAG) where depending on how often this failure occurs in the product, a number is determined that goes from 0 to 10
8. They are the Controls that are installed in the machinery or process to prevent an error or deficiency of the process
9. They are the controls that are proposed and designed to detect a fault equal to the one the Amef is focusing on.
10.Detection: Severity according to a table (provided by the AIAG) where depending on the detection (which is had to detect a failure) in the product, a number is determined that goes from 0 to 10
11. It is the result of multiplying Severity x Occurrence x Detection
12. It is when an Activity is determined to lower the RPN (Priority Risk Number) here it is briefly explained what will be done to reduce it
13. Here is written the name of the person responsible for the activity and the date of completion of the activity to reduce the RPN
14. Here the activities that will remain permanent to eliminate this failure are defined
15. Here the severity is evaluated again after the activities carried out and after a time defined by the person in charge and by the multidisciplinary team
16. Here the occurrence is evaluated again after the activities carried out and after a time defined by the person in charge and by the multidisciplinary team
17. Here the detection is evaluated again after the activities carried out and after a time defined by the person in charge and by the multidisciplinary team
18. Here the RPN (Priority Risk Number) is evaluated again after the activities carried out and after a time defined by the person in charge and by the multidisciplinary team
All Amef must have an Original Issue date, Level, Edition, Reason for the new change and the date of the last change, as well as some control stamp (To avoid uncontrolled copies being distributed), it must have for which part numbers apply, clients or production projects, depending on the type of industry to which it is focused
Spc
(Statistical Process Control)
Practical Manual
1. What is the SPC
It is a statistical control system, where special or special care pieces are monitored and measured at random (after defining the characteristics), the SPC is carried out, where it helps us to control the process as well as its variations of the product in process and your checkpoints,
2. What is an SPC for?
It helps us to take and take corrective actions to the process and improve productivity and helps reduce the costs of non-quality.
3. Who Uses the SPC
Any area of production where some special characteristics are processed and where measurements are taken to the product to obtain measurements, with the use of certified and reliable measuring instruments as well as with the use of specific measurement procedures where there is a standard way of measure the pieces in any shift of operation and with different people.
4. How often the SPC should be captured
It must always be Captured, as long as there are products in production that carry key characteristics and those defined by the multidisciplinary team to carry out statistical control of the product in process.
5. Types of Statistical Process Controls:
XR charts, Histograms, Pareto, Correlation
APQP
(Advanced Quality Planning)
Practical Manual
1. What is APQP
It is a system and method of steps to ensure that a certain product already designed and authorized can be processed in time and to be fully sure that the client is satisfied with the product that we are close to supplying, the translation of its acronym in English is "Planning Advanced Product Quality "
2. Phases of APQP
- Product Planning Design Processing Program Design Process Validation Program
3. Goals of the APQP
Complement and promote customer satisfaction and that your product is fully programmed and meets all your requirements.
4. What complements the APQP
- FMEA of Design and Process Drawings and Drawings of the Product to be Developed Authorization of Drawings and Specifications Specific customer requirements Tooling Development Program Minutes of meetings with the departments. Support and production Flow diagrams Raw material and component specifications Certification of materials suppliers List of critical or special characteristics to take care Customer authorization of Drawings and Specifications Purchase orders List of materials Feasibility analysis in the plant processes Control plan Process instructions Involvement of the Management in the Draft
