![]() What do you think? Do you, or your suppliers, use these process improvement tools? Our consultants have developed these documents in a number of projects, with good results. ![]() I made this whole approach look very linear, but often those process improvement tools are developed at the same time. Customers (who need to know what specifications the manufacturer commits to, and who may want to audit the process controls).Purchasers (who need to buy the right components & materials).Maintenance technicians (who need to know what the settings should be on the equipment).Quality inspectors & engineers (who need to do some of the checks).Production operators (who need to achieve that plan and do some of the checks when appropriate).(It should also include inspection of completed products, obviously.)īased on the control plan, proper work instructions can be given to the main interested parties: Product controls - in this case, inspection of incoming components and inspection of some characteristics of semi-finished products.(Note that the mold and the materials also need to be checked regularly - it’s not only about the machine.) Process controls - in this example, what to check regularly on a die casting machine to ensure it works properly.This the basis for a good control plan - the central document that the factory should use to drive the process’ capability up (in other words, improve process controls so as to get better product quality). A ranking of the highest risks to watch out for.But an easier way to start is to include the issues that came up in the past… if that process has been in place for some time. In theory, it is a tool to think of issues that might come up in the future. Don’t expect a production supervisor or a quality auditor to do it nicely without prior training and experience. (I covered the Process FMEA in more detail here.)Ī word of caution. It is a living document and should be updated often. Detection - how likely is it to be caught before it has an impact?Īnd then, for each failure mode, it drives an action plan.Occurrence - how often it is expected to happen. ![]()
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