Control Plan for Manufacturing (Shop Order)—Key Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Basic Data Setup

View Part Setup     


Purpose: The purpose of this exercise is to verify the basic data setup for the part used in the control plan when triggers are used.

Menu Path: Quality Management/Basic Data for Quality Management

  1. Open the Quality Management window.
  2. Activate the Mandatory Part/Site/Manufactured part/Site window.
  3. Query for the part 29-321, Camshaft.
  4. Verify that the Shop Order Control Plan and Shop Order Create Analysis check boxes are selected.

General Exercise for Basic Data for Control Plan

Viewing Product Structure

Purpose: The purpose of this exercise is to view the product structure that will be used for the control plan.  

Menu Path: Manufacturing Standards/Structures/Product Structure

  1. Open the Product Structure window.
  2. Query for part no. 29-321, Camshaft.
  3. Verify that one component is shown (29-525, Camshaft, Blank).

General Exercise for Creating Product Structures

Viewing Work Center

Purpose: The purpose of this exercise is to view the work center to be used in the routings. 

Menu Path:  Manufacturing Standards/Work Centers and Production Lines/Work Center

  1. Open the Work Center window.
  2. Query for work centers Turning (CNCT), Heat Treat Outside Work Center (510), and Grinding (CNCG). These work centers will be used in the routing for the camshaft.

General Exercise for Setting up Work Centers

Viewing Routings

Purpose: The purpose of this exercise is to view the routing for the camshaft.  

Menu Path: Manufacturing Standards/Routings/Routing

  1. Open the Routing window.
  2. Query for part no. 29-321, Camshaft.
  3. Verify that operations 10 Turning, 20 Heat Treat, and 30 Grinding are shown.

General Exercise for Creating Routings

Viewing Norm Types

Purpose: The purpose of this exercise is to view the norm type that will be used for the test operation.  

Menu Path: Quality Management/Basic Data for Quality Management

  1. Open the Basic Data for Quality Management window.
  2. Click the Norm Type tab and populate it.
  3. Verify that a norm type for diameter (D) is shown.

Required Data

Creating a Manufacturing Control Plan for an Order-Handled Part

Purpose: The purpose of this exercise is to show how to create a control plan that is used for order-handled parts.

Note:  Creating a Manufacturing control plan for an order-handled part is essentially the same as creating a Manufacturing control plan for a production-scheduled part. 

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

  1. Open the Control Plan – Manufacturing window.
  2. Create a new record.
  3. In the Part No field enter 29-321, and in the Part Description field enter Camshaft.
  4. In the Part Revision field, enter 1.
  5. In the Responsible Person field, enter NIKI.
  6. In the Routing Revision field, enter * or select it from the List of Values. 
  7. Save the information. 
  8. A message will appear (Control Plan 1 exist for this Part No and Routing. System will create a new revision). Click OK.
  9. Verify that the control plan and checklist status have automatically been set to Created.
  10. Select a control plan line and then create a new record.
  11. In the Routing Operation No field, enter 30 or select it from the List of Values.
  12. In the Test Operation Description field, enter Measure Outside Diameter.
  13. In the Norm Type field, enter D (diameter) or select it from the List of Values.
  14. In the Data Type field, enter Variable.
  15. Enter 70.000 in the Outer Min field, 70.025 in the Nominal Value field, and 70.050 in the Outer Max field.

    Note: Outer limits can be used to enter the requirements from the customer, while inner limits represent internal requirements. You do not have to use both inner and outer limits.
  16. Select an inspection code with a fixed quantity of 3. 
  17. Select the SPC and Capability Indices check boxes. 
  18. In the Evaluation Measurement Technique field, enter Outside Micrometer.
  19. In the Process Characteristic field, enter Feed Rate.
  20. In the Product Characteristic field, enter No Chatter.
  21. In the Special Characteristic Classification field, enter No Burrs.


Note: The following are text fields, in which an entry is not mandatory: Engineering Drawing Reference, Machine/Process/Tool, Inner Target Cp, Inner Target Cpk, Outer Target Cpk, Outer Target Cp, and Reaction Plan.

  1. Save the information.
  2. Verify that the line status is set to Planned.

Main Exercises

Viewing and Editing SPC Setup

Purpose: The purpose of this exercise is to show how to edit the SPC setup for Variable and Attribute data types.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

  1. Open the Control Plan – Manufacturing window.
  2. Select a control plan line. Then right-click and click Set up SPC Data. The Variable SPC Setup window appears.
  3. Under Control Chart, click Xbar and R Chart. 
  4. Under Show Tolerance Limit, click None.
  5. Under Show Sigma Limits, click None.
  6. On the Control Limits tab, calculate the control limits by clicking Calculated Limits.
  7. Under Mean and Standard Deviation, click Estimate based on data.
  8. Under Calculated Values, click All data.
  9. Click Save Settings and close the window.

Activating Alarm Rules 

Purpose: The purpose of this exercise is to show how to activate SPC alarm rules for Variable and Attribute data types. 

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

  1. Open the Control Plan – Manufacturing window.
  2. Select a control plan line. Then right-click and click Set up SPC Data.
  3. In the window that appears, click the Alarm Rules tab.
  4. Select the check boxes for the alarm rules you want to activate.
  5. Click Save Settings and close the window.


Adding a Control Plan Checklist

Purpose: The purpose of this exercise is to show how to add and approve a control plan checklist.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

  1. Open the Control Plan – Manufacturing window.
  2. In the header, right-click and then click Checklist. Another window appears showing the checklist items previously entered in the Basic Data for Quality Management window.
  3. Add at least one more checklist item manually. 
  4. Approve the checklist items by selecting the respective check boxes. 
  5. Save the information and then close the window. 
  6. Query for the control plan. 
  7. Verify that the checklist status has changed to Approved.

Activating a Control Plan

Purpose: The purpose of this exercise is to show how to activate a control plan.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

Note: This exercise describes how to activate a control plan, but you will not do that for part no. 29-321, Camshaft. If you have gone through the Overview of Quality Management Data lesson, you already have a similar control plan (revision 1) activated.

  1. Open the Control Plan – Manufacturing window.
  2. In the header, right-click and then click Active. Note: You cannot update control plan lines once the control plan has been activated. 
  3. Verify that the control plan status has changed to Active.

Creating a Control Plan for Manufacturing with Sample Frequency Trigger 

Purpose: The purpose of this exercise is to show how to create a control plan with sample frequency trigger.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

  1. Open the Control Plan – Manufacturing window.
  2. Search for the control plan for part 29-321 on your site. 
  3. Right-click and then click Copy Control Plan. 
  4. Enter today's date as the phase out date for the old control plan, verify that the new copy will get the next revision number, and click OK. 
  5. A message will appear saying that the new control plan has been created. Click OK.
  6. Activate the Sample Frequency Trigger/Define tab.
  7. Create a new line.
  8. In the Trigger Description field enter Start Shop Order. 
  9. In the Trigger Type field select Start Shop Order. 
  10. Save the information.
  11. Activate the Connect tab. 
  12. For data point 1, select the 1 - Start Shop Order check box.
  13. Save the information.
  14. Verify and approve the checklist.
  15. Activate the control plan.

Note that to test this control plan you should create a shop order, release it,  and reserve and issue the shop order material. The analysis will then be created automatically, and you can go directly from the Shop Order window and register the results in Analysis Results - Shop Order.