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【正文】 ess ? When there is a quality problem there is an opportunity to improve the control plan and the work instructions APQP Links to Control Plan F i r s t/ L a s t Pi e c eM i s ta k e Pr o o fi n gC o n tr o l Pl a nP/ M C h e c k l i s tQ u a l i ty C h e c k l i s tControl Plans ? Includes product and process special characteristics. ? Includes SPC requirements. ? Follows flow of process flow chart and PFMEA. ? May require customer approval. Types of Control Plans ? Prototype build control plan(s) ? Prelaunch control plan ? Production control plan Prototype Build Control Plan ? A description of the dimensional measurements. ? Material tests – Functional tests that will occur during prototype build. Prelaunch Control Plan ? Description of dimensional measurements, materials, and functional tests. ? Adds additional product and process controls. ? Purpose is to contain potential nonconformities utilizing: – More frequent inspections and/or tests. – More inprocess and finsl inspection and/or check points. – Statistical evaluations. – Increased audits. Production Control Plan ? Update prelaunch control plan. ? Add: – Sampling plans – Control method – SPC, inspection, attribute data and mistake proofing. – Reaction plan ? Nonconformances clearly identified, quarantined and disposition made. ? Requires customer approval unless otherwise specified. Control Plan Use ? Initial: To document and municate initial process control. ? Next: Guidance in controlling processes and to ensure product quality. ? Last A living document reflecting current methods of control and measurement systems used. Multiple Molds, Tools, Dies and Patterns ? Complete dimensional layer required from one part from each cavity as a minimum. ? Supplier must identify specific cavity for each part submitted. Part Submission Status ? Never ship production parts before receiving customer approval. ? Supplier must ensure that future production continues to meet customer requirements. ? No production parts can be shipped until approval is received. Automotive Documentation Development Develop Process Flow Listing Check for Customer Requirements Enter Every “Major” Process from Flow Listing into FMEA Form Give careful consideration to what you consider a “Major” process Develop FMEA Element for Every Process Use the appropriate RPN numbers and considerations of other appropriate information / data to determine Critical characteristics Develop the Control Plan with Critical Characteristics Develop control mechanisms appropriate for Critical characteristics. Give careful consideration to defining Control Plan stages Prototype
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