Quality Progress - January 2016 - 39

BACK TO BASICS Best of JUNE 2015 BY CHRIS HERMENITT 1+1 = Zero Defects Reduce defects, partner your control plan with PFMEA A CONTROL plan is a document that ing and injecting the plastic for a simple and reaction plans also are included in helps you plan and allows you to control transparent ruler. The overall size of the the control plan. The reaction plans give the products you make and the processes ruler is important for the customer. If the instructions regarding how to react to a used during the creation of those prod- ruler is too small or too large, it will be in- failure (quarantine the product since the ucts. It consists of the product description accurate. If you look at the PFMEA for the last inspection and notify the supervisor). and the process characteristics necessary ruler, it will list various failure modes with The control plan gives detailed instruc- to ensure the quality of the final product. the effects of the failures and their causes, tions to the employees about how to imple- This information is an important ad- and it will list the prevention controls and ment the controls defined in the PFMEA, the detection controls. ensuring alignment between the PFMEA, dition to the detection and prevention the shop floor and proper execution of the controls listed in the process failure mode and effects analysis (PFMEA), and the two Process and results documents are meant to be used together. Prevention controls focus on the pro- Because it is a supplement to the PFMEA cess and detection controls focus on the output of the process, controlling the and not a replacement, everything on processes's results. In this example, we process characteristics is more important the control plan must be shown on the consider a prevention control, monitor- than controlling the product characteris- PFMEA: It explains the why and what of ing the machine settings, and a detection tics. This is how pairing the control plan the process and product controls, while control, measuring the size of the ruler. with the PFMEA can save an organization the control plan explains how they should The control plan would provide more controls. Because product quality is only an money: They identify the prevention con- be implemented, how often, how many information and connect the controls to trols and implement them by monitoring and the what if analysis. the process and product itself. On the con- the process itself. This is completely different from Consider an example of the relation- trol plan, the machine settings would be a ship between the PFMEA and the control process characteristic, and the thickness isolating your focus on the process results plan. Specifically, the process of mold- of the ruler would be a product charac- (product quality). In this example, if teristic. The control the relationships between the machine plan includes the settings, other process inputs and the process and product product characteristics were completely specifications (shot understood, any defective products could size-5 grams, ruler be avoided. This is a method to reach zero thickness-3 mil- defects and reduce costs. limeters), measure- Control plans, in conjunction with ment techniques PFMEA, can be used to prevent problems (machine display, and save organizations money by identify- calipers) and the ing prevention controls and ensuring their sample sizes and in- successful implementation. QP spection frequencies (once per shift, five pieces per hour). The control methods (machine setting check sheet and statistical process control chart) CHRIS HERMENITT is the vice president of quality North America for Henkel Adhesive Technologies in Madison Heights, MI. He is a doctoral candidate at Northcentral University in Prescott Valley, AZ, and he earned his master's degree in engineering management from Eastern Michigan University in Ypsilanti. He is a senior member of ASQ and an ASQ-certified quality technician. January 2016 * QP 39

Table of Contents for the Digital Edition of Quality Progress - January 2016

According to Plan
Solid Proof
Use Your Head
Stakeholder Management 101
Customer Delight
All About Data
Eight Simple Steps
Minimizing Chaos
Take Note
Pyramid Scheme
Assessing Failure
Which Six Sigma Metric Should I Use?
Turning ‘Who’ Into ‘How’
In the Beginning
Outputs and Outcomes
That’s So Random—Or Is It?
Understanding Variation
Improving a System
Putting It All on the Table
Know the Drill
It’s Fun To Work With an F-M-E-A
Solve Problems With Open Communication
Tell Me About It
Separate the Vital Few From the Trivial Many
To DMAIC or Not to DMAIC?
Breaking It Down
Smart Charting
1 + 1 = Zero Defects
QFD Explained
Curve Your Enthusiasm
Make a Choice
What Is a Fault Tree Analysis?
Successful Relationship Diagrams
The Benefits of PDCA
Creative Combination
Return on Investment
The Art of Root Cause Analysis
Why Ask Why?
Get to the Root of It
Checks and Balances
Calculated Risk
Sufficient Evidence
Sample Wise
Clearing SPC Hurdles
Supplier Selection and Maintenance
Team Advantage
Building a Quality Team
Plan Experiments to Prevent Problems
Substantiation Test
Training Day

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