CONTROL PLAN 1 Purpose of process control is

CONTROL PLAN 控制計劃 1

¬ Purpose of process control is : 藝流程控制系統的目的是 ： – Control Variation 控制差異 – Protect customer from defective products 避免向客戶提供有缺陷的産品 Controlling the production processes instead of inspecting the finished products 要控制生産過程而不是檢驗加 後的産品 2

A control plan is a written summary of the system used to control production parts and processes 控制計劃是一份書面的系統概要，用來控制生産零部件 和 藝過程 – Addresses the important characteristics and requirements of the product 闡明産品的重要性能和技術要求 – Aims at minimizing variation 旨在將變差減至最低限度 – Focuses the team on value-add control methods 將小組的注意力集中在增值的控制方法上 3

Production Control Plan / 生產控制計劃 – Requirement/要求 • Systems for controlling parts and processes 控制零件和過程系統 • Includes receiving inspection, manufacturing processes, assembly, packaging, etc. as applicable 包括驗收，製造過程，裝配，包裝等適用項目 – Purpose/目的 • To control the production run 控制生產運行 4

¬ Identify a core team and appoint a leader 組成一個核心小組並指定一個組長 – representatives from groups involved in product and process design, and representatives from all phases of the manufacturing process 來自産品和過程設計的小組代表，以及來自生産製 造過程各階段活動的代表 – e. g. product design engineering, manufacturing engineering, industrial engineering, quality, manufacturing personnel, etc. 例如參與産品設計 程，製造 程， 業 程，質 量，製造等方面的人員 – train team if necessary 必要時對核心小組進行培訓 5

¬ Understand the product requirements 瞭解産品的技術要求 – – Obtain list of CTQs 獲取重要質量特性(CTQs)清單 Obtain information from design reviews 從設計評審中獲取資料 Obtain lessons learned, warranty info, etc. from similar products 從類似産品中取得經驗教訓和保證資訊等 Obtain or create the Process Flowchart 獲取或編制過程流程圖 6

+ Include all steps such as: receiving, inspecting, moving, storing, setting up, fabricating, assembling, packing, etc. 包括所有步驟如：驗收，搬運，貯存，機 器設定, 製造，裝配，包裝等 7

¬ Define characteristics to be controlled and methods for controlling them 確定要控制的特性和控制方法 – – must include special or key characteristics designated by the customer or internally 必須包括顧客或內部指定的特殊特性或關鍵 特性 include other characteristics designated for control by the customer or internally 包括顧客或內部要求控制的其他特性 8

¬ Suggestion 建議 – – Do your work on scratch paper first: do not use the control plan form as a worksheet 先在草稿纸上拟订，不要直接填写控制计划 表 Do the control plan work on the scratch paper version of the process flowchart 根據草稿紙上的過程流程圖制訂控制計劃 9

¬ Update the control plan as the product or process changes, or as new issues emerge 當産品或過程有改變，或是出現新的問題時， 要修訂控制計劃 – the control plan is a living document throughout the product life cycle 在産品整個壽命周期，控制計劃 始終是一份動態文件 10

ELEMENTS OF A CONTROL PLAN 控制計劃的要素 Header Information 標題資料 Product/ Process description 產品/過程 描述 Product/Process Characteristics 產品/過程特性 11 Control Methods 控制方法

Header Information 標題資料 4 4 4 Control Plan document number for tracking 控制計劃文件編號，可追溯 Part number/product number and change level 零部件编号/產品編號和更改番號 Part name or description 零部件名稱或說明 Supplier name and plant 供貨人姓名和 廠 Supplier code (from customer) 供貨人代碼(來自顧客) 12

Header Information 标题资料 4 4 Name and phone number of key contact (in our plant) 主要聯繫人姓名和電話號碼(廠內的) Names and phone numbers of core team members 核心 作組成員姓名和電話號碼 Approval date 批准日期 Reference document 參考文件 13

Product/Process description 產品/過程描述 ¬ This section identifies all parts/components and associated process steps that are in need of control. 確定了需要控制的所有零件/部件以及相關 序。 14

¬ Part/Process Number 零件/過程編號 4 4 4 Reference number to a process flowchart and/or assembly drawing 參照過程流程圖和/或裝配圖上的編號 • e. g. process step 14 for part 3 might be recorded as 3/14 例如製造 3號零件的第 14道 序可以記作 3/14 Applicable drawings and flowcharts should be easily tracked from the control plan 應很容易從控制計劃中查到適用的圖紙和流程圖 There should be no ambiguity 不應有含混不清之處 15

¬ Process Name/Operation Description 過程名稱/操作說明 4 4 4 Describe the operation or process step concisely 簡要說明操作或 序 The description should match the description in the process flowchart 此項說明應與過程圖中的說明相符 Recommended that you use the format verb+object 建議使用動詞+賓語格式 • e. g. move parts to assembly area 例如：把零件搬到裝配區 16

¬ Machine, Device, Jig, Tools for Manufacturing 製造用機器、裝置、夾具、 具 4 4 Identify the machine used in the process step 確定在 序中使用的機器 Be specific: if only certain machines out of many are used for this part, identify the specific machines in the control plan 具體說明：如果製造該零件時只需使用多台機器中的某些機 器，就要在控制計劃中具體說明 • e. g. mold machines #15, 16, 17 例如: 成型機#15，16，17 17

Notes/注意 ¬ ¬ If there is a move operation, please specify the type of vehicle used to move the material if this could affect product quality. 如果是進行搬運作業並會影響産品質量的話，不妨詳細 說明搬運物料用的車輛類型。 Measurement devices should not be listed in this column-they have their own column in the control methods section. 測量設備不應列入這一欄--在控制方法中有測量設備 一欄。 18

Product/Process Characteristics 產品/過程特性 ¬ This section contains a detailed description of the specific characteristics that must be controlled in order to assure quality. Each component and/or process step listed in the previous section might have several characteristics that need to be controlled. These are listed in this section, thereby adding detail to the previous section. 這一部分詳細說明了爲保證質量必須加以控制的 一些特性。上一節“産品/過程說明”中列出的每 個部件和/或 序可能有若干需要控制的特性。將 這些特性詳細列出。 19

¬ Number/編號 – Reference number to a product or process characteristic on a drawing, sketch, process flowchart, or other applicable document 在圖紙、草圖、過程圖或其他適用文件上給産品或過 程特性標出參考編號 • Adds more details to the part/process number 列出更詳細的零件/過程編號 • Applicable drawings and flowcharts should be easily tracked from the control plan 在控制計劃中應很容易找到相關的圖紙和流程圖 • There should be no ambiguity 不應有含混不清之處 20

¬ Product Characteristics 產品特性 – – Features, attributes, or properties of a part, component, or assembly 零件，部件，或元件的特性，屬性，或性能 Examples: 舉例： • Dimensions, weights, geometrical attributes 尺寸，重量，幾何屬性 • appearance items such as gloss 零部件外觀如光澤等 • material-related characteristics such as hardness 材料特性如硬度 21

¬ Process Characteristics 過程特性 – – 4 Process variables and parameters that have a cause and effect relationship with product characteristics 與産品特性有因果關係的過程變數和參數 Can only be measured at the moment it occurs 只能在發生的瞬間測得 Examples: 舉例： • Mold temperature 模具溫度 • Cycle time 週期時間 22

¬ Critical to Quality (CTQs) must be included and designated by the appropriate symbol in the control plan 重要質量特性(CTQs)必須包括在內， 並在控制計劃中用合適的符號指明 23

Control Methods 控制方法 ¬ Techniques for minimizing variation and controlling quality. 把變差減至最小和控制質量的技術 。 24

¬ Product/Process Specifications/Tolerances 産品/過程的規格/公差 – – – For the characteristics identified in the respective column 與各行中的特性相對應 Based on internal/external customer needs 以內部/外部客戶的需求爲依據 Obtained from drawings, design reviews, material standards, design standards, assembly standards 從圖紙，設計評審，材料標準，設計標準，裝配 標準中獲得 25

¬ Evaluation/Measurement Technique 评价/测量技术 – – + can be a quantitative or qualitative measure 可以是定量測量或定性測量 short description or reference number: 簡要說明或參考編號 • measurement gages, fixtures, etc. 量具, 輔具等 • measurement procedures 測量程序 Measure whatever characteristic (product or process) be used for control. 凡是用於控制的特性(産品或過程)都要測量 26

¬ Sample Size and Frequency 樣本容量和抽樣頻率 – – Used when sampling is part of control 當抽樣是控制的一部分時採用 Examples/舉例 • • 1 st piece per shift 每班首件 5 pcs every half hour 每半小時5件 1 st piece after setup 機器設定後首件 100% ongoing，100%連續全檢 27

¬ Control Method/控制方法 – There are three (3) types of control/有三種控制類型 • Type 1 --to prevent defects 類型1 --預防缺陷 • Type 2 --to detect the cause of defects 類型2 --檢查産生缺陷的原因 • Type 3 --to detect defects 類型3 --檢查缺陷 4 Generally/一般來說 • type 1 controls are preferred the most, type 3 controls are preferred the least 第 1種控制方法是最可取的, 第三種類型的控制方法 是最不可取的 28

¬ Type 1 Controls--to prevent defects 第 1種控制方法--預防缺陷 – – – Error proofing, Poke-Yoke, color coding 差錯預防，防傻瓜，彩色編碼 Indexing features for orientation 定向用特徵 Smart bins /定位銷 Operator instructions /作業指導書 Preventive maintenance /預防性維護 29

¬ Type 2 Controls--to detect the cause of defects 第 2種控制方法--檢查造成缺陷的原因 – – SPC and pre-control 統計程序控制與預先控制 process (parameter) controls 過程(參數)控制 30

¬ Type 3 Controls--to detect defects 第 3種控制--檢測缺陷 – Inspection 檢查 – Successive verification 連續驗證 – Random functional checks 隨機功能檢查 31

¬ The control method should be continually evaluated for effectiveness 應當不斷評價控制方法的效力 – – – Monitor process capability 監測過程能力 Monitor control charts 監測控制圖 Update control plan whenever a product or process change occurs 産品或過程一有變化，就要修訂控制計劃 32

¬ Reaction Plan/反應計劃 – Corrective action to be performed to prevent nonconformance from reaching the customer 採取糾正措施，防止不符合要求的産品到達客戶手中 • prefer actions that prevent defects altogether 優先採取能完全防止缺陷的糾正措施 • prefer actions that keep the process in control 優先採取使過程受控的糾正措施 • be sure to mark and quarantine nonconforming product (according to procedures) 標出並剔除不合要求的産品(根據程序) 33

• The persons closest to the process (i. e. the machine operator, supervisor/foreman, etc. ) should perform the action 最接近過程的人(也就是機器操作員，主管/領班等) 應當執行糾正措施 • Document what was done in reaction and keep records 在反應計劃中完成的 作應編制成文件並保留記錄 34