How to Design and Implement a Dynamic Control Plan

Why Should You Attend:

FMEA and the control plan are both major elements of advanced quality planning (AQP). They are both part of a planning process that can also include quality function deployment (QFD), or the house of quality.

This webinar training will discuss how to design a dynamic control plan that combines FMEA and the control plan by extending the FMEA to encompass the elements of the control plan and create a living document that helps to drive continual improvement.

Areas Covered in the Webinar:

1. AQP as a form of management of change (MOC), which recognizes that any change in a system creates a risk of unforeseen consequences
2. FMEA and the control plan are key elements of AQP, along with quality function deployment
• QFD outputs are inputs to FMEA
• FMEA outputs are inputs to the control plan
• The control plan defines process control methods, sampling plans, gages, and out of control action plans
3. Critical product characteristics can affect regulatory requirements or safety, and significant characteristics can affect customer satisfaction
4. The FMEA assigns failure modes severity (S), occurrence (O) and detection (D) ratings on a 1 to 10 scale, with 1 being best and 10 being worst
• Their product is the risk priority number (RPN) on a 1 to 1000 scale.
• RPN is not however everything. Any failure mode whose severity is 9 or 10 requires attention due to the potential consequences of failure
• The Army's Risk Management process, a free (public domain) resource, offers a simpler alternative to FMEA, especially when detection and occurrence ratings are difficult to quantify
• The Army's Risk Management process adds the principle that risk is not just a function of the individual likelihood of occurrence (the occurrence rating in FMEA) but also the number of opportunities for failure. This in turn requires engineering controls or error proofing to make failures impossible if the job is done frequently, or we are producing hundreds of thousands of parts
5. The FMEA and control plan can be combined to create a dynamic control plan.

Who Will Benefit:

All manufacturing companies will benefit from this training. The following job functions should attend:

• Manufacturing
• Quality
• Design
• Process Engineers
• Product Managers
• Anybody who is involved in AQP or design or process planning.

William Levinson
Principal Consultant, Levinson Productivity Systems

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 is The Expanded and Annotated My Life and Work: Henry Ford's Universal Code for World-Class Success.

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