Marrying the PFMEA & Control Plan: A Dynamic Control Strategy

Jd Marhevko, , VP QLMS/EHS, Accuride Corp, Saline, MI, USA

Keywords: Risk Based Thinking, PFMEA Control Plan Combination, Core Tools

Industry: All

Level: Basic


Risk & Change: Practical quality tools amped up manage product and process risk in an efficient and effective manner

Why: The Dynamic Control Plan (DCP) is a blend of the Process Failure Modes Analysis (PFMEA) and Control Plan (CP) into one document! It entirely eliminates the need for a stand-alone Control Plan. By essentially bolting on a few columns to the PFMEA, the CP is more powerfully enabled to effectively prevent and/or detect the failure modes that it is originally designed to manage. This little-used but Automotive Industry Action Group (AIAG) approved format can reduce hundreds of hours of engineering/quality time in document preparation. It largely mitigates disconnects in the Corrective Action/Preventive Action (CA/PA) analysis process. Participants will actually draft a DCP sample from a model provided in this interactive session. This engaging session leaves people motivated and with a plan of how to simultaneously reduce complexity while improving upon the efficiency and effectiveness of their quality management system.

Session Description: Come celebrate the union of the PFMEA and the CP! See how the Dynamic Control Plan (DCP) combines both tools into ONE enabling the savings of hundreds of hours of Engineering time, reducing the risk of documentation errors, and, actually improving QMS effectiveness while reducing repetitious work. This hands-on session will show you how you can benefit from the DCP!

  • Process Failure Modes Effects Analysis (FMEA): High level overview of PFMEA column content. Not designed to be an in-depth session of each PFMEA column
  • Control Plan (CP): High level overview of CP column content. Not designed to be an in-depth session of each PFMEA column
  • Dynamic Control Plan (DCP): Step by step blend of the two documents per general AIAG standards; no column will contextually be left behind. Participants will actually engage in completing 2-3 lines of a DCP for modeled items including variable and an attribute features
  • Benefits Review: Participants will discuss pros/cons of the DCP format including:
  • Pros: Some positives include reduced overall time in document management, reduced duplication of data collection, reduced risk of document alignment, Improved utilization in CA/PA analysis, etc

Cons: Some cons that need to be managed include transitioning the silos of engineering and quality teams into one effective group and managing customer expectations of independent formats, etc.

  • Type of Forum: This is a course/workshop with interactive discussion
  • Length of Presentation: 45 minutes
  • Learning

Outcomes: To help practitioners understand how the DCP can be positively leveraged to 1. Reduce business complexity, 2. Increase effectivity of both the PFMEA and CP formats. 3. Mitigate system cross-referencing errors. 4. Increase risk-based thinking