Initial Exercises—Quality Management 2 (Purchasing)
Initial Exercises
Purpose: The purpose of these initial exercises is to
demonstrate
the basic functionality of Quality Management for Purchasing.
The following exercises are included:
IMPORTANT |
These initial exercises are intended for
instructor use.
If you are a student, 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. |
Purpose: The purpose of this exercise is to introduce
the student to the basic functionality of design FMEAs. Note: The steps
involved in setting up process FMEAs are similar to the ones described below.
Prerequisites:
The part shown below is required for these exercises and has already been
entered in the Racing TM database.
Part Name |
Part No. |
Operation |
Area of Concern |
Valve Cover |
29-320 |
Supplier Die-Casting Process |
Oil leaks and reduced oil pressure due to faulty magnesium valve
covers. Cracking has been a problem in the past.
|
Menu Path: Failure Modes and Effects Analysis/FMEA Basic
Data/Basic Data for FMEA
Manufacturing Standards/Structures/Product
Structure
Manufacturing Standards/Design Failure Modes and Effects Analysis/Design FMEA Graphic
Manufacturing Standards/Design Failure Modes and Effects Analysis/Design
FMEA Effects Analysis Graphic
Steps: To complete this exercise, perform the following
steps.
- Setting up basic data—Open the Basic Data for FMEA window
and click the Classification
Criteria tab.
- Select a line and create a new record (F5).
- Enter a value in the Class Criteria field and a description in the Class
Description field (for example, Critical,
Major, Key, or Minor).
- Click the Checklist Templates tab.
- Select a line and create a new record (F5)
- Enter a sequence number, checklist question, and checklist comment.
- Save the information (F12).
- Creating
an FMEA header—Open the Product
Structure window.
- Query (F3) for part no. 29-320, Valve Cover.
- Click the Design FMEAs tab and create a new record (F5).
- In the Alternate field, select the a structure alternate from the List of
Values (F8).
- In the FMEA Level list, select Component.
- Save the information (F12).
- Verify that the FMEA status shown in the Status field has changed to
Created.
- Adding a checklist—Select a line on the Design FMEAs tab
of the Product
Structure window.
- Right-click and then click Design FMEA Checklist. The Design
FMEA Checklist
window appears.
-
Enter at least one new checklist line. You can also delete checklist lines.
-
Select the Item Approved check boxes to approve the respective
checklist items. Then save the information (F12) and close the window.
- In the Product
Structure window, verify that the checklist status has changed to Approved.
- Query (F3) for part no. 29-320, Valve Cover, in the Product
Structure window. Verify that the
checklist status has changed to Approved.
- Adding a function—Open the Design FMEA
Graphic window and query
(F3) for part no. 29-320, Valve Cover.
- Expand the graphic structure shown on the left and select the structure
alternate. A
window appears on the right.
- Select a line and create a new record (F5). Enter a function (for example,
Seal)
and a function description (for example, Maintain Oil Pressure).
- Save the information (F12). The function now appears in the graphic structure
on the left.
-
Entering a failure mode—In the Design FMEA Graphic window,
select the Seal function you just created in the
graphic structure on the left.
A
window appears on the right.
-
Select a line and create a new record (F5).
-
Enter a failure and a failure description (for example, Loss of Oil
Pressure).
-
In the Occurrence field, select a value from the List of Values (for example, 7– High –
Repeated Failures).
-
Save the information (F12).
-
Entering a cause of failure—In the Design FMEA Graphic
window, click the Causes tab.
-
Select a line and create a new record (F5).
-
Enter a cause and a cause description (for example, Machine Not Calibrated).
-
Save the information (F12).
-
Entering an effect of failure—In the Design FMEA Graphic
window, click the Effects tab.
- Select a line and create a new record (F5).
- Enter an effect and an effect description (for example, Out of Tolerance).
- Select a severity from the List of Values (F8) (for example, 8 – Very High).
- Select a classification criterion from the List of Values (F8).
- Save the information (F12).
- Expand the
graphic structure on the left and verify that the causes and effects have been
added.
- Entering controls and recommendations—In the Design
FMEA Graphic
window, select an effect in
the graphic structure on the left (the lowest accessible level). A window appears on the right.
- On the Controls tab, select a line and then create a new
record (F5).
- Enter a control and a control description (for example, Inspection).
- In the Detection field
, enter a value from the List of Values (F8) (for example, 2 – Very High).
- Save the information (F12).
- Verify that the risk priority number (RPN) is calculated in the RPN field. If you
have used the examples in this exercise, the RPN should be 112
(8*7*2). (Severity = 8, Occurrence = 7, and Detection = 2).
- On the Recommendations
tab, select a line and then create a new record (F5).
- Enter a recommendation and a recommendation description (for example,
Nondestructive Testing, NDT).
- Enter a responsible person and a target completion date.
- Save the information (F12).
- Expand the graphic structure on the left and verify that the controls and recommendations
have been added.
- Viewing the graphic analysis—Open the Design FMEA Effects Analysis Graph window and
query (F3) for part no. 29-320, Valve Cover. A graph appears displaying severity and
occurrence. The effects in the upper right corner are the most serious ones.
- Close all windows.
Purpose: The purpose of this exercise is to familiarize
the student with the basic functionality of Purchasing control plans.
Note: This initial exercise is very similar to creating
a control plan for Manufacturing or Inventory.
Menu Path: Quality Management/Control Plan/Control
Plan – Purchasing
Steps: To complete this exercise, perform the
following steps in the sequence shown.
- Open the Control Plan – Purchasing window.
- Query (F3) for the control plan for part no. 29-320, Valve Cover.
- Point out the mandatory fields in the control plan header.
- Part No: 29-320, Valve Cover
- Part Revision: 1
- Responsible Person: NIKI
- Supplier for Purchase Part: Mag Cast, Inc. (entered from
the List of Values (F8))
- Right-click in the header and then click Checklist to create a
checklist. A new window appears.
- Show the students where to enter new checklist items. (Note: In this case, you cannot enter
any new items since the control plan has Active status).
- Close the Checklist window.
- Verify that the checklist status is Approved (because all checklist
items are selected).
- Verify that the control plan status is Active.
- On the Control Plan Line tab, select a control plan line and point out some
fields.
- Test Operation Description: Nondestructive Test
- Norm Type: C (crack) (entered from the List of Values)
- Data Type: Attribute
- Nominal Value: *
- SPC check box: Select it.
- Evaluation Measurement Technique: Visual
- Inspection Code
- Activate the control plan by right-clicking in the control plan header and then clicking Active.
(Note: This control plan already has Active status.)
- Right-click on the control plan line and then click Setup SPC Data.
A new window appears. Explain the different SPC setup options.
Purpose: The purpose of this exercise is to familiarize
the student with the basic functionality of creating analyses and entering test results for
a purchased part.
Menu Path: Purchasing/Purchase Order/Purchase
Order
Purchasing/Receipt/Register Purchase Order Arrivals
Purchasing/Receipt/Purchase Order Receipt
Steps: To complete this exercise, perform the
following steps in the sequence shown.
-
Open the Purchase Order window.
-
Create and release a purchase order for part no. 29-320, Valve
Cover.
-
Open the Register Purchase Order Arrivals
window and query for the purchase order for part no. 29-320, Valve
Cover.
-
Register arrival of the purchase order. To do so, first add arrival location
29-ARRIVAL in the Location No field. Note:
It is crucial that you enter an arrival location.
-
Then select the line, right-click, and click Receive
Order. The Receive
window appears.
- Click OK to complete purchase
order arrival.
- Open the Purchase Order Receipt window and query
for the purchase order.
- Right-click and click Create Analysis. The Create Analysis – Purchasing window appears.
- Select or clear the Print Test Instruction check box.
Then click OK.
- A message appears informing you that an analysis has been
created and asking you whether you would like to enter test results. Click Yes.
The Analysis Results – Purchasing window appears.
- Verify that the status of the test operation line is Incomplete.
- Select the Attribute test operation line, and enter the number of defects in your sample in the
Nonconformities (c, u) field.
- Right-click on the test operation line and then click Complete Registered Results. Verify that the status for the test operation
line has
changed to Complete.
- Right-click in the header and then click Confirm Registered Result.
Verify that the status of the test operation line has changed to Confirmed.
Purpose: The purpose of this exercise is to familiarize
the student with the basic functionality of creating control charts for a purchased part.
Menu Path: Quality Management/Control Plan/Control
Plan – Purchasing
Quality Management/Analysis/Analysis Results – Purchasing
- Open the Control
Plan – Purchasing window and query for part no. 29-320, Valve Cover.
- Verify that the control plan has Active status.
- On the Control Plan Line tab, select the Nondestructive Test control plan line.
Then right-click and click Create SPC Chart. The Create SPC
Chart window appears.
- Under Analysis Date, enter dates in the From and To fields.
- Click OK. The chart appears.
- View the chart. In accordance with the selection made during SPC setup, a u chart
is shown. One point for
each analysis appears on the x-axis.
- Verify that mean value, standard deviation, upper control limit (UCL),
centerline (CL), and lower control limit (LCL) are
calculated and shown in the left part of the window.
- Verify that the diagram status is Out of Control if at least one
analysis falls outside the control limits, or that it is In Control if all analysis
data is within the control limits.
- Take a closer look at the chart. Do you see any points out of control? Do
you see any obvious non-random patterns?
Note: You can also create a chart from the Analysis
Results – Purchasing window. To do so, select the test operation line, right-click, and
then click Create SPC Chart.