IMEG was hired by a marking and coding equipment manufacturer to develop Control Plans for their key manufacturing processes. This followed the development of PFMEAs for seven of their process flows.
THE PROBLEM
Low process yields affecting customer’s operating efficiency
Low confidence in existing process control methods, none established in some cases
Inability to determine upstream root causes affecting downstream process yields
Urgent need to analyze, evaluate and update existing process documentation
THE PLAN
Based on created PFMEAs, develop Control Plans for key manufacturing processes
Evaluate product and process documentation to understand and identify:
Product and Process specifications
Machine, Jig, Tool and Device usage, tolerances and limitations
Conduct cross-functional reviews with Process, Quality, Operations and Design teams to:
Assess process control methods currently implemented, identify gaps and concerns
Determine control method and evaluation/measurement techniques that will need to be set up to exercise process control
THE RESULTS
Developed Control Plan documentation for seven process flows
Audited currently deployed control methods and verified if those are effective and/or sufficient
In combination with developed PFMEAs and associated Risk Prioritization Numbers (RPN), compiled list of action items based on RPNs
Initiated projects aimed to mitigate failure modes and set in place new control methods that are related to high RPN ratings
