Work instructions needed on PFMEA and Control plans?

Hi all,

Just looking for some guidance really. I have been given the job to review our control plans and PFMEAs and have noticed when going through, that we do not reference any works instructions relating to the process. We have a few hundred works instructions relating to the different types of processing/testing. So the question is do you need to reference works instructions on the PFMEAs and CPs? We are IATF16949 accredited and this have never been picked up on any surveillance/recertification audit for many years, even when we were TS16949 accredited.

Many thanks
B

I have seen some control plans that reference work instructions, but it is not a requirement. It is usually a choice made by the originator as being simpler than explaining the control method or reaction plan in greater detail.

Agree with Miner, referencing them provides a more complete picture, depending on your IT documentation structure, ensuring that the referenced documents are updated and reflected in the PFMEA and Control Plan is essential.

Hope this helps...
optomist1

necessity to mention reference documents is listed in new handbook now. For DFMEA :
and PFMEA

in examples of spreadsheet it is also mentioned:

SO auditors or wery precise customer may requiere it to mention

AndrewK said:

necessity to mention reference documents is listed in new handbook now. For DFMEA : View attachment 30049 View attachment 30050
and PFMEA
View attachment 30051
in examples of spreadsheet it is also mentioned:
View attachment 30052
SO auditors or wery precise customer may requiere it to mention

Click to expand...

Hi Andrew,

Thanks for your useful incite. I'm assuming this is to the "new" AIAG/VDA Combined approach? Our control plans are based on the blue book (4th ed), is this a requirement in there? I've read the book searching for this, but cannot find anything unless I'm missing something.

bruc3y said:

Hi Andrew,

Thanks for your useful incite. I'm assuming this is to the "new" AIAG/VDA Combined approach? Our control plans are based on the blue book (4th ed), is this a requirement in there? I've read the book searching for this, but cannot find anything unless I'm missing something.

Click to expand...

This is a new requirement. It is not in the 4th edition. Thanks @AndrewK for the information.

@bruc3y please note that the PFMEA guidance does use the word MAY versus the DFMEA, which uses the words NEED TO BE and SHOULD.

Miner said:

This is a new requirement. It is not in the 4th edition. Thanks @AndrewK for the information.

@bruc3y please note that the PFMEA guidance does use the word MAY versus the DFMEA, which uses the words NEED TO BE and SHOULD.

Click to expand...

Hi Miner,

Many thanks for clarifying, its much appreciated. Exactly what I needed.

B

is FMEA 4th edition still in use in Automotive? i thought that all customers already demand a new ones at least how it was announced Implementation strategy before. The rule was like - for running programs keep 4th- new ones should be used with new one. But OK, I'm glad that question is resolved

AndrewK,

My experience as a tier 2 is that most of my German customers ask for the AIAG/VDA combined whilst everyone else asks for the AIAG 4th edition.

If we had no German customers we would still use the AIAG 4th edition for all FMEA's but as an organization we have had to make the stand that new FMEA's will be done to the AIAG/VDA 1st edition and dictate this to all our customers.

bruc3y,

As Miner and optomist1 has said there is no requirement for PFMEA's or control plans to reference work instructions however it may make sense depending on your organization.

I worked at at organization that did not have work instruction references on control plans as it did not make sense to have work instructions for specific equipment; all we had was a CMM and lots of digital calipers. What we had instead were pictures on the control plan showing how to measure the features requested. However, the few CMM measurements did reference a specific program if required.

I am now at another organization that does reference work instructions on the control plan and we are starting a PFMEA project to redo all PFMEA's from scratch. It will make sense to reference work instructions as detection controls in our case.

Referencing document is method of protection against, overlooking the fact, that it has been lost or unnecessary creating new document covering subject described by already existing document.
Both cases I've observed in my professional life.
I am not thinking here on control plan only, but generally system documentation.
It helps personnel to learn all details of new job.
It is also beneficial for internal auditors to prepare for and carry on audit.

Our manufacturing process audit we have started from document review.
Cross check of PFMEA - control plan, whether they match.
Next stage was crosscheck of control plan - instruction.
Before we have appeared on work station, discrepancies were observed.
Then work instructions, we have seen in office, were not these one we saw on work station.

Without referencing, you won't find it.