Control Plan for Purchasing—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/Purchased part/Site window.
  3. Query for the part 29-OSP.
  4. Verify that the Purchasing Control Plan and Purchasing Create Analysis check boxes are selected.


General Exercise for Basic Data for Control Plan

View Supplier

Purpose: The purpose of this exercise is to view two suppliers to be used in later exercises.

Menu Path: Purchasing/Supplier/Supplier

  1. Open the Supplier window.
  2. Query for supplier 29-001, AAA Heat Treat, and supplier 29-002, Mag Cast, Inc.
  3. Verify that the suppliers exist.

General Exercise for Setting up a Supplier

Viewing Supplier for Purchase Part

Purpose: The purpose of this exercise is to view the suppliers for purchase parts who will be used for the control plans.  

Menu Path: Purchasing/Purchase Part/Supplier for Purchase Part

  1. Open the Supplier for Purchase Part window.
  2. Query for part nos. 29-OSP and 29-320. 
  3. Verify that suppliers are attached to these parts.

General Exercise for Supplier for Purchase Part

Viewing Norm Types

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

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 norm types for hardness (Rc) and cracks (C) are shown.

General Exercise for Entering Norm Types

Main Exercises

Creating a Control Plan for Purchasing (Part 1)

Purpose: The purpose of this exercise is to show how to create a control plan for purchased parts.

Note:  Creating a control plan for Purchasing is very similar to creating a control plan for Manufacturing and Inventory.

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

  1. Open the Control Plan – Purchasing window.
  2. Create a new record. 
  3. In the Part No field enter 29-OSP, 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. Under Supplier for Purchase Part, enter AAA Heat Treat in the Supplier No field 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 Supplier. 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 Test Operation Description field, enter Hardness Test.
  12. In the Norm Type field, enter Rc or select it from the List of Values.
  13. In the Data Type field, enter Variable.
  14. Enter 56 in the Outer Min field, 58 in the Nominal Value field, and 60 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.
  15. Select an inspection code with a fixed quantity of 3. 
  16. Select the Capability Indices check box.

  17. In the Evaluation Measurement Technique field, enter Rockwell Hardness Tester.

    Note: The following are text fields, in which an entry is not mandatory: Engineering Drawing Reference, Process Characteristic, Product Characteristic, Special Characteristic Classification, Sample Frequency, Inner Target Cp, Inner Target Cpk, Outer Target Cpk, Outer Target Cp, and Reaction Plan.

  18. Save the information.
  19. Verify that the line status is set to Planned. 

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 – Purchasing

  1. Open the Control Plan – Purchasing 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.

Creating a Control Plan for Purchasing (Part 2)

Purpose: The purpose of this exercise is to show how to create a control plan for purchased parts.

Note:  Creating a control plan for Purchasing is very similar to creating a control plan for Manufacturing and Inventory.

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

  1. Open the Control Plan – Purchasing window. 
  2. Create a new record.
  3. In the Part No field enter 29-320, and in the Part Description field enter Valve Cover.
  4. In the Part Revision field, enter 1.
  5. In the Responsible Person field, enter NIKI.
  6. Under Supplier for Purchase Part, enter Mag Cast, Inc. in the Supplier No field 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 Supplier. 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 Test Operation Description field, enter Nondestructive Test.
  12. In the Norm Type field, enter C (cracks) or select it from the List of Values.
  13. In the Data Type field, enter Attribute.
  14. In the Nominal Value field, enter *.
  15. Select an inspection code with a fixed quantity of 1. 
  16. Select the SPC check box.
  17. In the Evaluation Measurement Technique field, enter Visual.

    Note:     The following are text fields, in which an entry is not mandatory: Engineering Drawing Reference, Process Characteristic, Product Characteristic, Special Characteristic Classification, Sample Frequency, Inner Target Cp, Inner Target Cpk, Outer Target Cpk, Outer Target Cp, and Reaction Plan. 
  18. Save the information.
  19. Verify that the line status is set to Planned.

Viewing and Editing SPC Setup 

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

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

  1. Open the Control Plan – Purchasing window.
  2. Select a control plan line. Then right-click and click Set up SPC Data. The Attribute SPC Setup window appears.
  3. Under Nonconformities, click c chart. 
  4. Under Show Sigma Limits, click None.
  5. On the Control Limits tab, calculate the control limits by clicking Calculated Limits.
  6. Under Mean and Standard Deviation, click Estimate based on data.
  7. Under Calculated Values, click All data.
  8. 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 – Purchasing

  1. Open the Control Plan – Purchasing 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 – Purchasing

  1. Open the Control Plan – Purchasing 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 – Purchasing

Note: This exercise describes how to activate a control plan, but you will not do that for part nos. 29-OSP, Camshaft, and 29-320, Valve Cover. 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 – Purchasing 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 Purchasing 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 – Purchasing

  1. Open the Control Plan – Purchasing window.
  2. Search for the control plan for part 29-OSP with supplier AAA Heat Treat 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 Every Arrival.
  9. In the Trigger Type list box select At Arrival.
  10. Save the information.
  11. Activate the Connect tab.
  12. For data point 1, select the 1 - Every Arrival check box.
  13. Save the information.
  14. Verify and approve the checklist.
  15. Activate the control plan.

Note: In order to test this control plan you should create a purchase order, release it, and receive it. Then the analysis should have been created automatically, and you can go directly from the Purchase Order Receipt window and register the results in Analysis Results - Purchasing.