Dynamic Control Plans Drive Continuous Improvement

Duration: 60 Minutes
Failure mode effects analysis (FMEA) and the control plan that defines critical to quality process activities and their required controls are both parts of Advanced Quality Planning (AQP). The close relationship between the FMEA and the control plan suggests their combination into a dynamic control plan (DCP); a living document that supports continual improvement and reflects changes in the FMEA.
Continuous Improvement Management System
Product ID: 507673
Objectives of the Presentation
  • Attendees will learn the basic elements of advanced quality planning (AQP). These include:
    • Quality Function Deployment (QFD, House of Quality)
    • Design FMEA
    • Process FMEA
    • Control Plan
  • FMEA basics and beyond, including limitations of the risk priority number (RPN) in risk assessment
  • The control plan and its elements, including control factors and control methods, along with requirements for sampling, measurements, and measurement systems analysis (MSA)
    • Awareness of non-statistical controls that are often more effective than statistical ones
  • Combination of the FMEA and the control plan to obtain a dynamic control plan
Why Should you Attend
Advanced Quality Planning (AQP) is an important, and sometimes mandatory, activity that begins with identification of customer needs and wants through quality function deployment (QFD, House of Quality), continues with design and process failure mode effects analysis, and delivers a control plan for process activities that affect the critical to quality (CTQ) characteristic. Attendees will learn the basics of FMEA, and how to combine FMEA with the control plan to obtain a dynamic control plan that evolves as the FMEA is updated.

Areas Covered
  • Role of FMEA and the control plan in advanced quality planning (AQP)
  • Critical and significant characteristics, which are collectively known as critical to quality (CTQ) characteristics whose conformance, must be assured for product safety and customer satisfaction. CTQ characteristics are assessed in the FMEA and must be controlled as defined by the control plan
  • The FMEA identifies potential failure modes, and the failure mechanisms responsible. It prioritizes failure modes through the risk priority number (RPN), the product of the severity, occurrence, and detection ratings
    • RPN is not a perfect approach, however, because it is (first of all) the product of three ordinal numbers. As an example, a severity rating of 10 (jeopardizes human safety) is not twice as bad as one of 5, it is orders of magnitude worse than 5. In addition, RPN does not account for the frequency with which we are exposed to the risk. This leads in turn to the need for engineering or error-proofing controls that make failures and mistakes impossible
    • Army Techniques Publication (ATP) 5-19, "Risk Management," is a public domain alternative to FMEA, and it is much simpler. It may be useful depending on the application
  • The FMEA's requirements are deployed into the control plan in the form of controls for activities that affect CTQ characteristics. These controls are traditionally measurements of product conformance, and statistical process control. Non-statistical control methods (such as error proofing) are however often more effective, and should be used whenever possible
  • The FMEA's rows can be extended to include the control plan to create a dynamic control plan. The importance of treating it as a living document, i.e. one that drives improvement and is updated accordingly, as opposed to a once-and-done activity cannot be overemphasized
Who will Benefit
  • Quality managers and engineers
  • Quality management professionals
  • Engineers and technicians with quality management system responsibilities
  • Design engineers
  • People with responsibilities for ISO 9001:2015 or ISO/TS 16949 compliant systems
  • VP Engineering
  • Office Managers & Admin
  • Others with responsibility for advanced quality planning (AQP)
Topic Background
The dynamic control plan is an improvement on traditional quality planning that combines the Failure Mode and Effects Analysis (FMEA) with the control plan to create an integrated planning and continuous improvement tool.
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  • Presentation handouts in downloadable PDF format will be updated on your OCP Account within 24 hours of the purchase of the product
  • Download the Certificate of Attendance and Purchase Invoice from your OCP Account after 48 hours of the product Purchase
  • Please share your valuable Feedback at the end of the session
Instructor Profile:
William Levinson 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 holds degrees in chemistry and chemical engineering from Penn State and Cornell Universities, and night school degrees in business administration and applied statistics from Union College, and he has given presentations at the ASQ World Conference, ISO/Lean Six Sigma World Conference, and others.


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