Linking DFMEAs and Control Plans

A natural link exists between FMEAs and Control Plans.

The purpose of a Control Plan is to:

• Minimize variation.
• Provide a structured approach for control.
• Establish a well thought-out reaction plan.
• Document and communicate failures and improvements.
• Enhance customer satisfaction.

The primary reason for developing a Control Plan from a DFMEA is to use the DFMEA for setting process control procedures and identifying primary control points for the process the product will be made on.

• A Control Plan linked to the DFMEA provides a structured documentation and communication vehicle for the process control group.

Key components of a Control Plan include the:

• The control factor.
• Specifications and tolerances of control factors.
• Measurement system or technique.
• Sample size and sample frequency.
• Control method.
• Reaction plan.