Process Consideration Methods

Process documentation includes the most important document for any automobile industry which is known PPAP (Production Part Approval Process) documents. PPAP consists of various steps which a followed by the suppliers and manufactures ensuring that all the safety risks are eliminated from each component used in the automobile, before the product gets to the dealer/distributor and customer. It is very necessary for manufactures and suppliers to communicate and approve the production designs and processes not only before the manufacturing is done but also during and after it and PPAP is the standardize system or process which make this thing possible and in a systematic manner. Created in would like to advance a clear comprehension of the necessities

Design Records (Drawings/ESK) – Under design records it is necessary to provide the printed copy of the drawing. A customer drawing copy is sent along with the Purchase Order (PO) if customer is the one responsible for designing of that part/component and in case supplier is the one who is responsible for designing then this is a drawing released in release system of supplier. Every single feature must be road mapped or ballooned to relate with the inspection results which includes standard tolerance notes and specification, and everything which is relevant to the design of the part.

9.3. DFMEA (Design Failure Mode and effect analysis) – It is the utilization of Failure Mode and Effect Analysis (FMEA) principles which is aimed at the design stage of the process and it helps to understand where the product design could fail. This DFMEA technique assist the design team to record what they suspect and know about a product’s modes of failure preceding the finishing of product design, and after that this information is used to mitigate or design out the causes of failure.

Ideally, the DFMEA begins at the early stages of concept development, as this in turn helps the design team to eliminate or reduce the chances of failure and develop new and more robust

Control Plan – A Control Plan is the one in which all the methods are being defined and the customer-specified requirements are being compiled and every organization shall have a control plan. This control plan is applicable to all the three phases included in the product development process and those are prototype, pre-launch and production. Uses of Control Plan are:

• Initially to document and communicate initial process control.

• Next is guidance controlling processes and to ensure product quality.

• Last is a living document reflecting current methods of control and measurement systems used

The objective is to help in manufacturing of the products having high quality as per the requirements of the customer. This is achieved by presenting a structured approach for the selection of design and how the value added control methods are to be implemented for the whole system. To minimize the process and product variation a summary description of the system is being provided in control plan. In case any process goes completely out of control or become incapable, then immediately a reaction plan is to be activated and complete inspection is to be carried out. A control plan basically is the written description of the system which can be used for controlling processes and parts. A single control plan is applicable to a family or group of products that have the same process for production and are produced at the same