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ControlPlanandFMEA
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Gabriel14years,2monthsago.

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July27,2002at11:53am#31453

Kofi
@Kofi
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CananybodyhelpmetobetterexplainthedifferencebetweenControlPlanandaFMEAtomysubsuppliers.IwanttoknowiftheControlPlanhastomatch
theFMEA,andinwhatways.
Thanks.

July27,2002at1:42pm#31455

Eileen
@Eileen
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Kofi,
Theintentofaprocesscontrolplanistocontroltheproductcharacteristicsandtheassociatedprocessvariablestoensurecapability(aroundtheidentified
targetornominal)andstabilityoftheproductovertime.TheprocessFMEAisadocumenttoidentifytherisksassociatedwithsomethingpotentiallygoing
wrong(creatingadefectoutofspec)intheproductionoftheproduct.TheFMEAidentifieswhatcontrolsareplacedintheproductionprocesstocatchany
defectsatvariousstagesontheprocessing.

Eileen

July29,2002at11:53am#31478
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Gabriel
@Gabriel
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Kofi:
Acontrolplansayswhoshallcontrolwhatandhow,howmany,howoften,andwhatshallbedoneifitisfoundtobeoutofexpected,allthisforeachstepof
theprocess,andincludingbothproductandprocesscharacteristics.

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AFMEAisapreventiveandimprovementtoolthathelpyouunderstandwhatcangowrongwiththeprocess(failuremode),why(causes),whatmayhappen
then(effect),andhatareyoudoingtoverifythattheprocessisnotgoingwronginthisway(controlsfortheprocessandfortheproduct).
ThecontrolsinthecontrolsfieldoftheFMEAarethosethatyouareactuallyperforming,sotheyshouldbealreadystatedinthecontrolplan.TheFMEA
canbeagoodtooltodefineandimproveacontrolplan.IfyouaredevelopinganewprocessthatwillneedanewcontrolplanandyouaredoingtheFMEA,
thecontrolsfieldwillbeblank.Becauseofthat,allthedetectionfactorswillbe10and,becauseofthat,manyNPRmaybetoohigh.Assessingthe
severity,theproductofseverityxoccurrence(somehowlinkedwiththesignificanceofthecharacteristic)andtheNPRwillhelpyoudefineimprovement
actionssuchascontrolsforeachcharacteristicateachstepoftheprocess.Thenyoucantakethesecontrolsasthabasisforthecontrolplan.(Idonotmean
thataddingcontrolsistheonlyorbestimprovementactionpossible.Modifyingtheprocesstoremovecausesandworkingwiththedesigntominimizethe
effects,forexample,canbemoreeffectiveandeficientthanaddingcontrols.Butmostlikelyyouwillstillneedcontrols,asEileensaid,toverifythatthe
processisdoingwhatyouexpecteditwoulddo).Inthesameway,whenyourevisetheFMEA(forexamplebecauseofacustomercomplaintorbecauseof
acorrectiveorimprovementaction)youmayfindthatthecontrolpalnneedstobereviewdaswell(youmayneedtoaddacontrol,oryoumayfindthatafter
animprovementyoucanremoveacontrolorreduceitsintesity).
Asyousee,theFMEAandtheControlPlanaretwocompletelydifferenttools,buttheyarelinkedbytheprocessandbythecontrols.
Doyouthinkthismayhelp?
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