1factory understands that the amount of paperwork required to submit a PPAP to your customer can be overwhelming. In this help document, we will outline how to streamline the process of creating Process Flow Diagrams, PFMEA's & Control Plans.
1 PPAP Processes
The first step in creating Process Flow Diagrams, PFMEA's & Control Plans is to setup your master list of process in the PPAP Processes tile within the Master Data tab.
1.1 Process Flow Master:
Once you are in the PPAP Processes tile, you can begin to identify the processes within your operation to produce your product. To create a new process, simply click the New Process Flow button. From there, fill in the details related to the process being created and then click GO.
1.2 PFMEA, Process Control Plan & Product Control Plan Master:
Once a process has been created, you can begin to build your Master PFMEA and Process & Product Control Plan. To do so, click on a process from the list you wish to dive into. From there, you can manage the core documents for the selected process.
To add a new failure mode within a process, simply click the Add Row button on the left ribbon. To remove a row, select the row you wish to delete and click the Remove Row button. Failure modes added to the Master PFMEA will automatically populate when creating a part-specific PFMEA. You can also add and remove rows within the plan.
RPN Color Scheme:
- GREEN: Less than 100 RPN
- YELLOW: 100 - 150 RPN
- RED: Greater than 150 RPN
Note: 1factory has taken the lesson learned approach when it comes to the PFMEA & Control Plans. The intent is to build out your Master PFMEA to the fullest and as lessons are learned, add them into the Master PFMEA. By doing so, this assures that moving forward these failure modes are realized across all parts which utilize the specific process.
To add a new control within the Master Process Control Plan, simply click on the add row button on the left ribbon. You can also remove rows by choosing the row you wish to remove and clicking on the remove row button. Process controls that have been added to the Master Process Control Plan, will automatically be populated when creating a part specific Process Control Plan. Within the part specific plan, you can also add and remove rows.
Note: The Master Process Control Plan is meant to be used to identify standard process related characteristics such as injection pressure, forces, temperatures etc...
Under the Master Product Control Plan you can define a commonly used Machine, Control Method & Reaction Plan.
2. Creating the part specific Process flow, PFMEA & Control Plan:
2.1 Defining the Operations sequence:
To create your part-specific Process Flow, PFMEA, and Control Plan, start by defining the order of operations within your manufacturing plan. Operation sequences can be set in the shaded operations column of the manufacturing plan. You can define operations per feature or use the group edit feature to streamline the process.
2.2 Defining the Processes:
The next step is to indefinity which process occur in each operation sequence. To do so, go to the PPAP tab of the plan. Once in the PPAP tab, choose which process occurs at each operation sequence.
2.3 Review the PFMEA, Process Control Plan & Product Control Plan:
Lastly review the rest of the documents. The data from the Master List will be pulled into each of the correlating documents. The user can edit, add & remove rows in the PFMEA and Process Control Plan as they see fit.