How do FMEA and Control Plan fit together?

Carol,A control plan is constructed at the conclusion of a Process FMEA. It’s not used in a product or application. When looking at the Process FMEA, causes are flagged which have either preventative or inspection controls. Any high risk causes that do not have controls are potential process failure points. A control plan are all of the actions that will be done to minimize and/or mitigate the potential process failures. These actions appear sequentially in the controls section of the FMEA. They could include such activities as set-up checks and tests, mistake proofing activities, or online inspections with pertinent criteria. Good Luck,Ken

Carol/ Allen,
Thought I’d pen my thoughts on this.
FMEA tell you, what can go wrong, how severe the effect, how frequent the defect/cause occurs and current controls available. This is a parent document to feed into your control plan which is more of How to do the current controls effectively. eg
For a FMEA on Tea preparation, failure mode may be too sweet, cause could be more sugar , current controls could be taste before serving to spouse / sugar quantity control.
The control plan now details the frequency of taste checks, the ‘gage’, the acceptable standards of sweetness and what to do if the tea is less sweet or more sweet. (THIS is EFFECTS ‘Monitoring-Control’)
The cause is the one which really needs to be controlled. The cause is the sugar quantity, so Control plan tells you the correct quantity in grams, the actual way of weighing the sugar, frequency of checking the weight etc.
So the real ‘difference’ between FMEA and Control plan is in the deploymewnt level of quality control.
In some operations of Auto companies, they have ‘married’ the features of both FMEA and Control plan and called this DCP (Dynamic Control plans).
Hope this helped…
Ram

Carol
Correct, but you need to distinguish the fact that there are 2 types of FMEA. One is for design and the other is for process.

Carol
To my understanding, FMEA is a tool to study the failure mode and freqeuency for happening, how to detect the failure, to identify the most Risk-taking process or material inputs. Therefore, it is different from the control plan.
First, FMEA is used when the process is new or something wrong happen for my process.
Secondly, FMEA is in Measure/measure stage,
Finally, Control plan is to fix the good result by SPC…..If anything special, the operator can easily see and correct.
I don’t the above explaination can satisfy you or not? If you would like to discuss with me, email.

In fact the Control Plan is a result of a previous FMEA. The team encharged of a project uses the FMEA as a tool to identify the potential failures that must be addressed and the controls that will keep it under control. These results in a Control Plan that must be available at the shop floor and for everyone responsible to run the process. The FMEA must not be available for everyone.
In a regular basis the FMEA must be revised and all changes are updated on the Control Plans. Therefore there is a dynamic link between the two documents. 

With the FMEA you and your team narrow in on the numerous failures/problems, prioritize their importance (RPN) and begin with solutions to resolve the failures/problems.
The Control Plan is basically your working document guiding you and your team through making those recommended solutions to resolve your problems/failures.  You decide which issues to resolve, who will do it, how often etc.  The control phase is your time to gradually let go of the project and turn the Control back to the process owner.  The control plan also has tests in it to prove your savings after the changes have been made.

I’m an engineer with ten years of experience in the manufacturing field, and have been part of a APQP team in my company.
Here is my theory of FMEA- Failure mode Effect Analysis  1) Design a FMEA that best fits your process, begin with a Flow chart diagram which draws up your process being studied.
2) Start by using your part print to highlight all the dimensions of the part to be produced, than start with 1st operation and subsequent process and all the potential defects and thier causes and controls.
3) Develop RPN, BASE OFF SEVERITY,OCCURRENCE AND DETECTION.
After a FMEA has been developed, looking at your Control Plan, this will be your Production Process Control Driver or INspection plan.
Let me know if this sums up most of it.
 

FMEA is a living document in which potential failures are analysed and failure modes, their causes and their effects are prioritised for reducing the risk. The next document is Control Plan for controlling prototype / pre-launch / production parts. These are two separate documents and both are required.

FMEA is a tool that is used in the Analyze phase to help the project team identify all the factors that can influenec the
Project Y,assess the consequences of the effect,list current
detection methods,and identify possible action itens to mitigate the overall RPN rating.
 
 
The Control Plan is a summary of the items that must be accomplished by the Process Owner to sustain the project gain.
Identification of the critical Xs,operating setpoints,SOPs,
action items to take when the process drifts using control
charts,and a response plan would be included in a good control plan.

In some operations of Auto companies, they have ‘married’ the features of both FMEA and Control plan and called this DCP (Dynamic Control plans).
Hope this helped…
Ram
FMEA AND CP IN SAME FORMATE OR SEPARATE FORMATE?

The FMEA is a document where everything which could be wrong must to be analysed. What you will put in your Control Plan, depends wich standard your company is certificated. For ISO/TS 16949: 2002, for example, everything that you have in your control plan must be in the PFMEA. If you have Inspection plans and other kinds of control in your process to prevents products scraps, like machine timely maintenance, regulations and calibration of pressure controls, this controls must be included in PFMEA. But every control that you put in the Control Plan must have a capability study and MSA study (R&R).

FMEA, as name say, is a brainstorming process in which we all chance of product/process going wrong is thought, their effect analysed with level of severity, occurence and difficult level in detection of error.
where as control plan is reverse of this, its base plan which when followed will lead to controlled process in manufacturing and finally a good controlled product.
FMEA is what can go wrong and Control Plan is what is to be checked / controlled for good product.
For Eg. if you have to go to college in morning, you decide what are all factors like missing connecting bus, high traffic etc, may lead to late for college class. This comes under FMEA and actions like keep enough time margin, start early are part of control plan.
FMEA is concept/brainstorming/thought process for happening of defect while control plan is action/process spec control method details.
Hope, I am able to clear some doubts.