DSQR Training Control Plans HEATING, COOLING & WATER HEATING PRODUCTS DSQR Training Control Plans Bill Kennedy Corporate Quality

Control Plan Training Methodology For process control and improvement to be effective, a basic understanding of the process must be obtained. A multi disciplined team should be established to develop a Control Plan by utilizing all the available information to gain a better understanding of the process, such as: process flow diagram system/design/process failure mode and effects analysis special characteristics lessons learned from similar parts team’s knowledge of the process design reviews

Control Plan Training Methodology What is a Control Plan? A structured approach for the design, selection, and controlled methods used in producing a part. A Control Plan defines the operations, equipment, materials, processes, methodologies and CTQ’s integral to the manufacturing process. Control Plans are critical for planning a robust process. Control Plan should: List all the sequence and type of operations used in the process Must address and include the CTQ’s Include specifications, sampling strategy, control and reaction plans Include periodic conformance testing and product verifications Type and method of process and inspection equipment used

Control Plan Training Methodology The primary intent of Control Plans is to …. create a structured approach for control of the process and product characteristics, while focusing the organization on characteristics important to the customer. assure well thought-out reaction plans are in place in case an out-of control condition occurs and provides a central vehicle for documentation and communication of control methods. describe the sequence of process steps, methods, and actions required at each phase of the process including receiving, inprocess, out-going, to assure that all process outputs will be in a state of control.

Control Plan Training Methodology Control Plans Can be developed independently, but are a natural extension of an FMEA Assures a system is in place to control the risks of the same failure modes as identified in the FMEA. Special attention is typically given to potential failures with high RPNs and those characteristics that are critical to the customer. Inputs necessary to develop a Control Plan are: Technical specifications and drawings Process flow diagram DFMEA/PFMEA Details of measurement methods, equipments, fixtures, machines Sampling requirements and frequency, if any Reaction plans

Control Plan Training Methodology Benefits of a Control Plan include: Quality Formal structure provides a thorough definition and evaluation of the product and process. Describes the actions required at each phase of the process to ensure all process outputs will be in control Identifies key process characteristics and helps to monitor sources which can cause variation in product characteristics. Customer Satisfaction Control Plans focus internal resources on processes and products related to characteristics that are important to the customer. Communication As a living document Control Plan identifies and communicates changes in the product/process characteristics, control method, and characteristic measurement.

Control Plan Training Development Steps for control plan development Describe the process Finalize the characteristics to be controlled Plan the proper method of control Establish the reaction plan

Control Plan Training Typical Control Plan Format Page of Supplier Name: Control Plan Number Control Plan Revision Level Sup plier Key Contact/Phone Written by Date of last revision Delta Part Number Delta Part Revision Level Part Name Delta approval Approval date Process Number Process Name/ Operation Description Machine, device, jig, tools, make, model, asset #, etc Characteristics Methods Reaction Plan No. Product Product/Process Specification/ Tol erance Evaluation Measurement Technique (gage # if applicable) Sample Control Method Size Freq. Notes : 1 2 8 13 4 15 16 17 18 19 20 21 22 23 24 25 9 10 3 11 5 7 6 12 Note: Alternate formats can be used if they contain necessary information

Control Plan Training Typical Control Plan Format

Control Plan Training Typical Control Plan Format

Control Plan Training Typical Control Plan Format

Control Plan Training Group Exercise: In the assigned teams and using the information and template provided develop and draft a Process Control Plan.