The control plan is an important part of advanced quality planning (AQP). It describes how, in terms of measurement procedures and equipment, the process is to measure and control critical to quality (CTQ) product characteristics. The control plan is in turn the result of the deliverables from the Failure Mode and Effects Analysis (FMEA), which is another element of AQP.
The FMEA and the control plan can also both be shown in context with quality function deployment (QFD) or the house of quality. The voice of the customer as reflected in QFD is an input that defines critical and significant product characteristics for the design FMEA. The design FMEA provides inputs to the process FMEA, whose outputs dictate the nature of the control plan.
The tabular format of the FMEA includes a row for each part (or process step), its potential failure mode (how it can fail) and effect (the consequences if it does), calculation of its risk priority number (RPN), existing controls, and action plans to reduce the RPN. The dynamic control plan is a logical extension of the FMEA with additional columns for control plan elements such as the measurement method (gage, sample size, and sample frequency), gage capability, process capability, and out of control action plan. This makes the FMEA and control plan into a single entity.
The result is a living document that addresses the risks (in terms of severity, likelihood of occurrence, and likelihood of non-detection) of non-conformance of CTQ characteristics. "Living document" means it is updated to reflect changes and improvements in the product and the process. The dynamic control plan also supports ISO 9001:2015's provisions for actions to address risks and opportunities, and also knowledge retention.
Join expert speaker William A. Levinson to learn how the dynamic control plan fits into the quality management system to support AQP, and also supports ISO 9001:2015's provisions for activities to address risks and opportunities, and knowledge retention. Know how to calculate the risk priority number (RPN), but also recognize that some RPNs are more equal than others. That is, a RPN of 100 with 10 severity, 2 occurrence, and 5 detection requires far more attention than an RPN of 200 with 2 severity, 10 occurrence, and 10 detection. Go beyond textbook FMEA by recognizing that risk involves not only the individual occurrence rating but also the number of parts or transactions involved; that is, the number of times we are exposed to the risk. Know how to combine the FMEA and control plan to get a living document, i.e. one that is updated in response to changes in the process, product, or customer needs, that focuses priorities on critical to quality features and ensures closed-loop actions to reduce risks and improve quality.
Who Should Attend
William A. Levinson P.E.
William A. Levinson, P.E., is the principal of Levinson Productivity Systems, P.C. He is an ASQ Fellow, Certified Quality Engineer, Quality Auditor, Quality Manager, Reliability Engineer, and Six Sigma Black Belt. He is also the author of several books on quality, productivity, and management, of which the most recent ... More info