Great directions pointed out by Paul! With considering the actual capability of controlling the variations of ALL inputs and constraints of our knowledge (for unexperienced or unforeseen failure modes/causes, we don't know we don't know), some extent of inspections (and process behavior charts) on the outputs are inevitable, they are the necessary and complementary part for evolving control plan. Don't get me wrong, I fully agree with Paul's direction of put priority in prevention instead of inspection. In fact, most companies look down upon on execution of controlling the inputs, quality assurance audits because the leadership don't feel the pain directly. On the contrary, failures of scrap, rework and customer complaints draw more attention of leadership because its direct impact. This clip by Paul is a great education material for any organizations!
Michael - I have no disagreement with the process you describe, SPC charts are part of the solution with a control plan of inputs working together that is the cheapest way to minimise defects...
As ISO 9001 consultant, besides a Control Plan I’d like to have a register that demonstrates that the operator checks the variables with an agreed frequency. Thanks for your clear explanation
So many smaller companies waste their time and money just to get the 9001 certificate. Very few understand how to use it wisely! Very good explanation!
Paul, if R&D does not do DFMEA when they work on a prototype/pre-production stage product, how would you as a Production Engineer create FMEA for this product when it enters the production stage? Would you observe each step to understand what failures happen and the create FMEA? Thanks
Hi karol - even without the DFMEA the production engineer should still know the important variables in a process and know how to design good system of work to control them...
Great directions pointed out by Paul! With considering the actual capability of controlling the variations of ALL inputs and constraints of our knowledge (for unexperienced or unforeseen failure modes/causes, we don't know we don't know), some extent of inspections (and process behavior charts) on the outputs are inevitable, they are the necessary and complementary part for evolving control plan.
Don't get me wrong, I fully agree with Paul's direction of put priority in prevention instead of inspection. In fact, most companies look down upon on execution of controlling the inputs, quality assurance audits because the leadership don't feel the pain directly. On the contrary, failures of scrap, rework and customer complaints draw more attention of leadership because its direct impact.
This clip by Paul is a great education material for any organizations!
Michael - I have no disagreement with the process you describe, SPC charts are part of the solution with a control plan of inputs working together that is the cheapest way to minimise defects...
As ISO 9001 consultant, besides a Control Plan I’d like to have a register that demonstrates that the operator checks the variables with an agreed frequency. Thanks for your clear explanation
I agree with that Josep, it's part of keeping control of the process....
So many smaller companies waste their time and money just to get the 9001 certificate. Very few understand how to use it wisely! Very good explanation!
Cheers Markus...
Well Done Paul very well presented as usual.
Cheers Mark, hope you DOE study is going well....
A decent FMEA doesn’t need a control plan and vice versa, depends on preference…Great video
Hi Stuart - I would say a decent FMEA creates a control plan, otherwise why did you do the FMEA?
Great vid. Anybody got links to the actual writing up of a controln plan.
Hi Holton - I do have video on that as well, I'll see if I can find it...
Paul, if R&D does not do DFMEA when they work on a prototype/pre-production stage product, how would you as a Production Engineer create FMEA for this product when it enters the production stage? Would you observe each step to understand what failures happen and the create FMEA? Thanks
Hi karol - even without the DFMEA the production engineer should still know the important variables in a process and know how to design good system of work to control them...