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TOOLS;
SPC, MSA, FMEA,
APQP/CONTROL PLAN
CQI Wessex - 11 December 2012
John Skinner
rdaconsultancy.com
AUTOMOTIVE PROGRESS
SINCE 1990
Best selling car in the UK in 1990
Ford Fiesta sold in EU
1.4, 1.6 CVH engines were very harsh and
had early failures (valve guide wear,
dropping valve seats damaging the engine).
Rust was still a problem, though better
than the 1970s & 80s.
Radio-cassette, some speaker adjustments, maybe electric windows. No a/c
and definitely no climate control. No airbags, little in the way of crumple
zones. Central locking on higher end models. Door mirrors had remote
adjustment on top models. Security was very poor cars like the XR2 were
being stolen by joyriders on a regular basis (epidemic levels in some areas).
Car insurance costs on hot models went through the roof. No ABS, stability
control etc.
Cost around 8500 roughly equivalent to 15000 in todays prices
WHAT CHANGED?
Improvements demanded by legislation (emissions,
ISO/TS16949
AUTOMOTIVE
APQP; Advanced Product Quality Planning
REQUIREMENTS
FMEA; Failure Mode & Effect Analysis
Control Plan
SPC; Statistical Process Control
MSA; Measurement System Analysis
These require a team approach (cross functional
Concept
Initiation
/Approval
Product Quality
Planning Timing
Chart
Program
Approval Prototype Pilot Launch
Planning
Planning
Product design
Process design
Validation
Production
Feedback assessment & corrective action
Product Design
& Development
Verification
Product &
Process
Validation
Feedback Assessment
& Corrective Action
changes
project.
New design, technologies, material aluminium,
using self piercing rivets and aerospace sourced
epoxy adhesive
Advantages;
Thorough planning and improved decision making
Shorter development timescales
Simultaneous engineering (design & manufacturing)
Early procurement of long lead time tooling/facilities
Defined objectives, measured as project stages are
achieved
Defined project gateways, with key deliverables
Improved use of resources
Significant cost savings (known impact on company
finances)
Effective feedback & corrective action (enhanced with
use of computer systems)
DFMEA
DFMEA
DFMEA
DFMEA
Ignores manufacturing issues; i.e. manufacturing
PFMEA
A PFMEA will follow the stages defined for the
PFMEA
PFMEA
PFMEA
Control Plan
A documented description of the systems and
Control Plan
Control Plan
Part #:
Part Name/Description:
N/A
Prepared By:
Core Team:
xxxx
xxx, xxx, aaa,
bbb, ccc
#REF!
Supplier/Plant App./Date:
Vendor ID:
#REF!
Other Approval/Date:
Supplier Plant/Code:
#REF!
Oper. #
Process Description
Machine/Device/Jig/Tools
70
OP 70; Finish
machine
bearing bores
(CNC)
Characteristics
Item#
Product
Notes:
CC
Process
SC
CC
Process/Pdt. Spec./Tolerance
G.ID
75 +0.008 -0.000 mm
0.003 mm run out max
In cycle
gauging.
25mm/min,
CBN tip
(XYZ)
Control Plan
Date (Original):
xxxxx
CP001
Methods
Sample Size
Sample Frequency
Control Method
Reaction Plan
In cycle gauging.
100%
Control Plan
Identifies the controls required to ensure
Statistical Process
Control
Traditional inspection techniques (patrol
People
Equipment
Materials
Methods
Environment
Product
Manufacturing
Process
Customers
Identifying
changing
expectations;
direct feedback
on product quality
Inputs
Feedback from Customers
Goals of SPC
Statistical Process
Control
Taking action on the result of the output of a
Statistical Process
Control
Machining process;
part dimensions
vary from each other
Size
Size
Statistical Process
Control
Common cause variation; inherent in the process
Special cause
variation (or
assignable cause)
machine set up,
material change,
environment
Predictable ?
Time
Size
Time
Size
Statistical Process
Control
_
X Range Control chart
centreline
6 points in a row steadily increasing or
decreasing
2 out of 3 points more than 2 standard
deviations from the centreline (same side)
4 out of 5 points less than one standard
deviation from the centreline (same side)
Process Capability
Capability indices are able to summarise
Process Capability
Upper
specification
Lower
specification
Process variation
or spread
Tolerance
Capability Indices
6 (process variation)
_
_
Capability Index Cpk = USL x OR x - LSL
(largest of)
Capability Indices
If the process data has a normal distribution, the
1.33
63/1,000,000
1.67
0.6/1,000,000
2.0
0.02/1,000,000
Attribute Charting
Attribute data is the result of inspection or
Measurement System
Analysis
appraisers.
Typically 3 trials per appraiser
Complete the study using usual equipment and individuals
Gauge R&R
- Repeatability
- Reproducibility
- Part to part variation (how representative
the parts are; this will influence the results).
Gauge R&R
Acceptable Gauge R&R% results;
Up to 10% - generally acceptable
10 to 30% - may be acceptable based on
Use of Graphical
Techniques
There are many different methods for
Attribute Studies
Go/No-go gauging systems (acceptance
PPAP
PPAP
Acceptance of the PPAP detail is key for
project
Support the supplier approval rating (i.e. PSW
submission on time)
Trigger tooling payments to the supplier
(tooling will typically be owned by the
customer)
AUTOMOTIVE PROGRESS
SINCE 1990
Best selling car in the UK 2012 (to date) Ford Fiesta
Summary
In truth, many factors have influenced the
Questions
Thank you