Quality Control Questions

See this example it should answer all question.

great doc GA

Thank you Rakesh

Job.

Interesting.

If anybody has such a good quality plan as well as production or maintenance plan, let me know.

thank you.

Basically it goes back to quality theory. Quality is comprised of two concepts. Specification and Compliance. A control plan is a specification. Planning is mapping out how you are going to acheive control over the subject. A good plan takes into account all possible variables, and attempts to continuously improve the achievement thereof. The control plan details the variables, metrics, methods, tolerances, evidence of compliance, and applicable governing specifications, including the organizations quality policy and procedures.

For a specific project, it is best if you make the control plan before executing the project, but after management has made decisive and financial commitment, giving you the authority, and also so you don't get left holding the bag. After all, quality is a policy of management.

As for vendor control plans... remember that it is your organization that is specifying what quality is, for your quality program, for which you will be audited. If they meet your written standard, and you have evidence of that, then you are basically done. If the governing specification (such as ISO 9001:2000) that your vendors shall be qualified to provide the product or service, then you must have on file the documentation showing that they as a vendor meet your criteria. If they have a quality certification, that makes it easy, as you just need a copy of their cert.

Hope this is helpful; ask more questions if you found it to be so. I'm not that much of an expert, but did have to put all that together as a QA manager... We found a man who was a plant manager, And was an auditor for other organizations.. and he agreed to consult to us, and to perform our internal audits..so he was a very valuable resource.

Chris

Thank you Chrisg,

It is very help-ful. Rakesh also tried to help but I could not digest. It was very nice of him.

Job.

ISO 10005 would make a good starting point in answering your questions.

You can refer the following articles by ASQ http://www.asq.org/pub/qualityprogress/past/0802/81standards0802.html and http://www.asq.org/quality-progress/2008/11/standards-outlook/automakers-shift-manual-into-another-gear.html You can go through the article. The details can not be given (they are protected by copyright hence i can not enclose these) however these short articleas are in public domain,

Hi,

Have the below!!!

What is a control plan?

Control plan is one of the living document that specifically applicable for manufacturer who produces automotive products. This document is derived based on Design FMEA & Process FMEA. It is divided into three phase.

1 st phase - Prototype control plan - it is derived while the product in sample stage.

2 ndphase - Pre launch control plan - it is derived while the product is before serial production.

3 rdphase - Production control plan - it is derived while the product is ready for serial production.

Now a brief look over control plan --> This document indicates ,

What are the parameter to be controlled , By which method is to be controlled, What are the instrument to be used for controlling, Based on which sampling plan & frequency this to be controlled, What will be the corrective measures when it out of spec.

Why is it necessary to have one?

To control the process & product parameters of each process in a defined method..

What do you achieve by having one?

Variation in process, Reduction in Reject & Rework, Reduction in COPQ(Cost of Poor Quality), Good reputation from the client on site visit/audit...

For a specific project, when do you make a control plan?

Answer to this explained in the first query itself..

When should you ask your vendor for a control plan?

You can ask it from your vendor , when you're going to order for serial production but it is better to get it while asking for sample...

What if your vendor processed your order with out having or submitting a control plan?

You're authority to decide it.. whether to go with the vendor or not .....

Hope this will be an eye opener about control plan .. Anymore you needed reg this, you're welcome!!

Regards,

Hari

Well Explained!

Thank you Hari

Job.

Very nice explaination hari

But what points should I consider while designing a control plan.

Please give me one example if you have (specially for rejection).

Hello Sandeep,

As I said earlier, You have to take the outcomes of the Design FMEA & Process FMEA for designing the control plan .

FMEA --> Failure Mode & Effect Analysis

Note: For instance, From Process FMEA you can get the input of possible failures in each individual process... Here the control plan comes & answers how to control & evade the failures, By which sampling method, etc.., as depicted earlier..

Hari

Well said Hari.

But little disagree with underlined.

"Control plan is one of the living document that specifically applicable for manufacturer who produces automotive products."

Hello Rakesh,

Thanks for your comments!

As per ISO 9001:2008(Revised version of 9001:2000) standard- there is no need for control plan, but the same is mandatory for TS 16949:2002 standard which is exclusive for automotive products.

If you're manufacturing any components to the automotible vehicle such as Car, Bus etc., (Risk related with human life) then control plan is mandatory but the same is not mandatory for commodity products...

If you wish, you can also go with control plan for any products ... It's definitely ended up with good result... as i mentioned in the earlier message...

This is the reason, why I specifically correlate control plan with autombile products!!!

Hari

What is the business you are in? I am guessing you are not automotive related as you would already be versed in this philosophy / method of manufacturing control.

The example of the control plan is great, but I feel the level of basic questions you are asking will require you to either hire someone with this experience or you will need to get some education.

Understanding this is one thing but developing and implementing it is a fairly large task as I am assuming that the company you work for also does not understand therefore "buy in" will be a huge hurdle to get over. (Non automotive people sometimes are very unreceptive to change)

I am also guessing that your company is not ISO or QS certified.

Josh.