1、Control Plan TrainingControl Plan Training控制计划培训控制计划培训1Control Plan PurposeControl Plan Purpose控制计划的目的控制计划的目的nThe purpose of the Control Plan is to aid in the manufacture of quality products according to customer requirements.控制计划的目的是根据客户要求制造产品nA single Control Plan may apply to a group or family of
2、 products that are produced by the same process at the same location.单一的控制计划可以应用于在同一个地方用同样的工艺制造的零件族或者零件群组nThe Control Plan describes the actions that are required at each phase of the process including:material receiving,in-process,final shipping and any requirements to assure that all process outpu
3、ts will be in a state of control.控制计划描述不同工艺阶段的措施（包括：材料接收、生产过程、最终出货）和一些要求以确保所有的过程输出处于可控状态。2nThe Control plan is to be developed using a cross functional team per AIAG requirement.The creation and revision dates shall be listed.控制计划是由跨功能团队来完成。创建和版本日期都要列出。nThe process begins with the Flow Diagram.The s
4、teps and process controls are transferred to the Control Plan.过程是从流程图开始。所有步骤和过程控制都要被转换成控制计划。nAll Dimensions shall have a customer drawing balloon number(if applicable)identified.所有的尺寸规格都应该有一张顾客气泡图（如果适用）nAll Customer Special Characteristics shall be identified,when applicable.当适用的时候，所有的顾客特殊特性都应该被识别nA
5、ll gages/test equipment/mistake proofing etc.is identified.所有的量具/测试设备/防呆治具等应该被识别nProcess controls must be explicit.For example:过程控制必须是明确的。例如：PSI 312 15.6 or PSI 312 5%-these require operator calculation.这些要求工人计算。327.6/296.4 PSI or 468/156 PSI is preferred.327.6/296.4 PSI or 468/156 PSI是优选的。Scrap fir
6、st 5 shots(or parts)submit 6th to inspection for approval.报废前5个，第六递交申请批准。Thermolator set at 345/347.Mold face temp.286/295.调温器设定在345/347.。模具表面温度286/295.Control Plan AIAG FormatControl Plan AIAG Format控制计划格式控制计划格式3Control Plan AIAG FormatControl Plan AIAG Format控制计划格式控制计划格式Header Section抬头部分Main Body
7、 of Information主体信息4Control Plan-Header SectionControl Plan-Header Section控制计划控制计划-抬头部分抬头部分1 13 32 21)Type of CP(prototype,pre-launch,1)Type of CP(prototype,pre-launch,production)production)控制计划类型（原型机，预生产，控制计划类型（原型机，预生产，批量生产）批量生产）3)Part#with engineering rev.level3)Part#with engineering rev.level 零件号
8、码、版本、等级零件号码、版本、等级4 44)Part name(description)4)Part name(description)零件名（描述）零件名（描述）5 55)Plant location of manufacturing5)Plant location of manufacturing 制造工厂位置制造工厂位置 2)2)CP#for internal trackingCP#for internal tracking 内部追踪控制计划编号内部追踪控制计划编号7 77)Main contact person with tel.#7)Main contact person with
9、tel.#主要联系人电话号码主要联系人电话号码8 88)Team member names8)Team member names 团队成员名字团队成员名字9 99)Plant approval date(internal)9)Plant approval date(internal)工厂批准日期（内部）工厂批准日期（内部）101010)Other approvals i.e.head office,10)Other approvals i.e.head office,customer head office,etc.customer head office,etc.别的批准别的批准.例如总部或
10、者顾客总部等（假例如总部或者顾客总部等（假如适用）如适用）111111)Date of 111)Date of 1stst original CP original CP 原始控制计划日期原始控制计划日期101012)Date(rev#)of CP last update12)Date(rev#)of CP last update 最新更新日期最新更新日期121213)Customer engineering approval13)Customer engineering approval 顾客工程确认顾客工程确认131314)Customer quality approval14)Custo
11、mer quality approval 顾客质量确认顾客质量确认14146)Supplier Code i.e.DUNS#6)Supplier Code i.e.DUNS#制造工厂代码制造工厂代码.例如盾白氏号例如盾白氏号6 65Control Plan-Main SectionControl Plan-Main Section控制计划控制计划-主体部分主体部分15151717161617.Machine,device,jig,tool for mfg.17.Machine,device,jig,tool for mfg.机器设备、夹具、制造工具机器设备、夹具、制造工具181818.Cros
12、s reference number18.Cross reference number索引序列号索引序列号191916.Process description16.Process description过程描述过程描述202020.Process20.Process过程过程2121 21.SC,KC,CC item 21.SC,KC,CC item重要特性、次要特性、关键特性重要特性、次要特性、关键特性2222 22.Specification/tolerance 22.Specification/tolerance规格规格/公差公差2323 23.Measurement methods 23
13、.Measurement methods测量方式测量方式2424 24.Sample size&frequency 24.Sample size&frequency样本容量样本容量&频率频率2525 25.Control method 25.Control method控制模式控制模式262615.Process#15.Process#过程序号过程序号 26.Reaction plan 26.Reaction plan反应计划反应计划19.Product19.Product产品产品6n15)15)This item number is referenced from the Process F
14、low Chart.If multiple part numbers exist(assembly),list the individual part numbers and their process accordingly or reference BOM&color cross-reference matrices.此序号来自过程流程图。假如多个过程序号存在，列出单一的过程序号和它们相应的过程或者参考材料清单和颜色对照阵列。nExampleExample例如例如:OP 10,Incoming Inspection来料检验OP 20,Warehouse Storage仓库储存OP 30,R
15、elease Material for Production生产放料OP 40,Dry Resin Material干树脂材料OP 50,Injection Molding注射Part/Process Number过程序号7Process Name/DescriptionProcess Name/Description工艺名称工艺名称/描述描述n16)16)All steps in the manufacturing of a system,subsystem,or component are described in a process flow diagram.Identify the p
16、rocess/operation name from the flow diagram that best describes the activity being addressed.所有的一个系统、子系统、或者在过程流程图中描述的组件。确保过程/操作的名字和工艺流程图的一样。最准确地描述工艺。nExample:Example:Mold Part,Heat treat,Material receiving.8Machine,Tool,Jig DescriptionMachine,Tool,Jig Description机器、工具、夹具描述机器、工具、夹具描述n17)17)For each o
17、peration that is described,identify the processing equipment,e.g.,machine,device,jig,or other tools for manufacturing,as appropriate.对于每一个操作对应合适的过程设备。例如，机器、仪器、或者别的加工工具，视情况而定。nExampleExample例如例如:Machine#20 tool IS-IB,Mixer Group#23,Injection Mold machine#22注射机#22.9CharacteristicsCharacteristics特性特性n1
18、8,19,&20)18,19,&20)A distinguishing feature,dimension or property of a process or its output(product)on which variable or attribute data can be collected.Use visual aids where applicable.一个特征、尺寸或者过程性能或者产品输出。计量型或者计数性数据能够被收集。适用情况下，使用可视化工具。10Characteristic“Number”Characteristic“Number”特性特性“号号”n18)18)En
19、ter a cross reference number from all applicable documents such as,but not limited to,process flow diagram,numbered blue print(balloon or QA point designations),FMEAs,and sketches(computer generated or otherwise),if required.输入一个索引号。索引号来自所有的应用文件，例如（但不限于）过程流程图，气泡图，FMEA，和必要的时候，可以使用草图）11Characteristic“
20、Product”Characteristic“Product”特性特性“产品产品”n19)19)Product Characteristics are the features or properties of a part,component or assembly that are described on drawings or other primary engineering information.nListed here are Product Characteristics for which process control are routinely tracked duri
21、ng normal operations.nExample:Hole,Slot,length,width.12Characteristic“Process”Characteristic“Process”特性特性“过程过程”n20)20)Process Characteristics are the process variables(input variables)that have a cause and effect relationship with the identified Product Characteristic.过程特性是工艺参数（输入参数）。这些参数和对应的产品特性是有因
22、果关系的。nCharacteristics or features whose variation must be controlled to minimize product variation.特性或者特性的变异是必须被控制在最小的产品变异内。nA Process Characteristic can only be measured at the time it occurs.过程特性只能在出现的那时是才能被测量nExample:PSI,temperature,speed,cycle time.例如：压力、温度、周期。13Special Characteristic ClassSpeci
23、al Characteristic Class特征等级特征等级nUse the appropriate classification symbol(CC,SC or KC)to designate the type of special characteristic.使用合适的分级符号指定特殊特性的类型nKC=ImportantKC=Important.Monitors features that are representative of overall part function/appearance and/or tool integrity.KC=重要的。监控特征代表所有的零件功能/外
24、观和/或者工具的完整性。nSC=SignificantSC=Significant.Identifies features that are significant to maintain which,if discrepant,could hinder or affect the design or functional intent of the component.SC=重大意义的。鉴定的特征是对于假如出现差异后将导致阻碍或者影响组件设计或者功能意图的nCC=Critical.CC=Critical.Same as significant except these features ar
25、e related to Safety,Performance,or Government Regulated items.CC=决定性的（危险的）。和重大意义的一样，除了特征和安全、性能、或者政府法规的条款。nThese characteristics are variously termed by our customers as“Critical”,“Key”,“Safety”,or“Significant”.这些特征是 被我们的客户称为“决定性的”、“关键”、“安全性的”或者“重大意义的”nAffect customer safety,compliance with regulatio
26、ns,form,fit,function or appearance.影响想顾客安全、法规遵守、外形、装配、功能或者外观。14Methods“Product/Process/Specification/Tolerance”Methods“Product/Process/Specification/Tolerance”方法方法“产品产品/过程过程/规格规格/公差公差”nA systematic plan using procedures and other tools to control a process.系统的计划通过程序或者别的工具来控制过程nReflect statistically
27、sound sampling:Dodge-Romig(LTPD)AOQL,AQL,MIL-105E,MIL-414,Chain Sampling.统计抽样标准15Method“Product/Process Specification/Tolerance”Method“Product/Process Specification/Tolerance”方法方法“产品产品/过程规格过程规格/公差公差”nSpecifications/tolerance shall be obtained from the drawing,material standard,manufacturing,and/or a
28、ssembly requirements.规格/公差应该从图纸、材料标准、制造和或者装配要求中获得nExample例如:47.0/53.0 mm or 2916/311616Method“Evaluation/Measurement Technique”Method“Evaluation/Measurement Technique”方法方法“评估评估/测量技术测量技术”nIdentifies the measurement system being used.This could include gages,fixtures,tools and/or test equipment requir
29、ed to measure the part/process/manufacturing equipment.确保测量系统被使用。包括量具、夹具、工具和/或者测量零件/过程/制造设备要求的测试设备nExample:Izod impact test悬臂梁式冲击试验,Lab equip#11.17Method“Sample Size&Frequency”Method“Sample Size&Frequency”方法方法“样本容量和频率样本容量和频率”nList the corresponding sample size and frequency.列出对应的样本容量和频率nBe suspiciou
30、s of sample sizes of 5 hourly.This is probably an unnecessary cost.每小时5个样品是值得怀疑的。这可能是不必要的成本。nn=5 was chosen by SPC consultants to allow easy math calculation.通常过程研究人员选择N=5 作为简单的数学计算。nn=3 at significant changeovers is more economical and still allows for approximation to normality and an estimate of
31、variance.作为重大的转变N=3更为经济，且仍然考虑到接近常态和方差的估计。18Method“Detection Method”Method“Detection Method”方法方法“侦测方法侦测方法”nBrief description of how the operation will be controlled,including procedure numbers where applicable.简要说明怎样控制操作，包括程序编号（适用的情况）nMethod is based on effective analysis of the process and is determ
32、ined by the type of process that exists.方法是基于有效地过程分析和取决于现行的过程类型nControls can be:Statistical Process Control,Inspection,attribute data,mistake-proofing.控制可以是：统计过程控制、检验、计数性数据、防呆。19Reaction PlanReaction Plan反应计划反应计划nSpecifies the corrective actions necessary to avoid producing nonconforming products&st
33、ate that rework/repair requires customer approval 指定必要的纠正措施以防止生产不良产品或者申明要求得到客户批准返工或者维修。nIndicate the specific reaction plan number.指定特殊反应计划编号nAIAG requires that reaction plans specify:标准要求反应计划指定一下内容：Actions to be taken采取措施Who or what position is responsible for the decisions and actions.(i.e.Use,Scr
34、ap,rework:Setup,Operator,Quality Manager)谁是负责决定和措施的（使用、报废、返工：安装、操作人员、质量经理）nActions should be specific:措施应该具体化Hole undersize:replace cam punch/shutoff.9.50 dimension off,adjust ready-benders in 2 increments to nominal.Viscosity too thin:add PS01 in 1 gallon increments until Zahn cup reading is 18/19
35、seconds.20Common Difficulties with Control PlansCommon Difficulties with Control Plans控制计划常见的难点控制计划常见的难点nProcessing parameters that are too general to be of use.过程参数太泛而不能使用nFailure to identify key Customer and Processing characteristics.不能识别关键顾客特性和关键过程特性nVague reaction plans in the control plan:在控制计
36、划内存在模糊的反应计划 Adjust process parameters,Adjust set-up 调整过程参数，调整装夹nUndefined reaction plan responsibility:没有定义反应计划的负责人 Who is responsible for scrapping or reworking material?谁负责报废或者返工材料Who is responsible for adjusting the parameters or set-up?谁负责调整参数或者装夹21Wrap Up Why Have Control PlansWrap Up Why Have
37、Control Plans总结总结-为什么要有控制计划为什么要有控制计划nThey aid in the manufacture of quality product according to customer requirements.It allows this by providing a structured approach for the design,selection and implementation of value-added control methods for the total system.它有助于根据顾客要求制造有质量的产品。，它允许为设计和为综合系统增值控
38、制方法的选择和执行提供一个有建设性的方法nThe control plan does not replace the information contained in detailed operator instructions.控制计划不是替代细节操作说明书里面的信息nIts Living document to be maintained and used throughout the product life cycle.控制计划是活着的文件，需要在整个产品寿命周期内被维护和使用。BenefitsBenefits好处好处:nQuality Quality-The control plan
39、 reduces waste and improves the quality of products.The structured discipline provides a thorough evaluation of the product&process.It identifies key characteristics.质量质量-控制计划减少浪费和提高产品质量。建设性的纪律提供一个周密的产品和过程评估。它识别关键特性。nCustomer SatisfactionCustomer Satisfaction-Focus resources on processes&products related to characteristics that are important to the customer.顾客满意度顾客满意度-集中资源在过程以及对顾客重要的相关产品特性。nCommunicationCommunication-Living document that identifies and communicates changes in the product/process characteristics,control method and measurement.沟通沟通-活着的文件可用来识别和沟通产品/过程特性和控制方法以及测量变化22
