Instructor Guidelines GM-SI Flow, FMEA, Control Plans

Prior to the Workshop

Receive documents (PFD, PFMEA, PCP, Pre-test, Post-test)
Training needs verification, PR/R, call to SQE, call to PQE, call to client
Talk to customer to identify the portion of PFD, PFMEA, PCP that will be part of the
exercise
Make transparencies of the above portions of the documents for team review in
class
Workshop worksheet
Call checklist, workshop requirements, prepare attendance sheet
Day 1
Start

End

Description

8:30

8:45

8:45

9:00

Introduction
Agenda
Plant Mgr./Designate Opening Comments/
Introductions
Attendance
Icebreaker

9:00

9:30

Pre-test

9:30

9:35

9:35

9:45

9:45

9:55

9:55

10:05

10:05

10:15

10:15

11:15

11:15

12:15

Objectives
Understand and review Process Flow analysis
Understand and review supplier PFMEA
Review Process Control Plans and
relationships to Process Flow and PFMEA
Work instructions and Action plans
Zero Tolerance Presentation
Roles and Responsibilities of GM suppliers
Consequences of Spills
Break
Overview of Flow, FMEA, and Control Plans
Causes and Effects of poor documentation
What are the pitfalls of not having the process
fully defined? Incomplete?
Undefined process steps
Teamwork
Cross functional team composition
Functional roles of team members
Overview of Process Flow Diagram (PFD)
Objectives
Customer/Supplier relationship
Hidden factories
Reviewing the columns
Product (KPC), process (KCC) control and
special characteristics
Process flow implementation
Process Flow Diagram (PFD) Shop Floor Exercise
Point group to blank PFD form in Appx A

THE PIC GROUP

Reference
Material

Format

Slides # 1-8

Ppt

Slide # 9
Handout/Slide #
10

Ppt

Slide # 11

Ppt

Slides # 12-17

Ppt

Slides # 18-21

Ppt

Slides # 22-23

Ppt

.Doc/Ppt

Slides # 24-46

Slide #47-48
Blank PFD

ISSUE DATE: 31 MAY 04, REV #5

Ppt

Instructor Guidelines GM-SI Flow, FMEA, Control Plans

Start

End

Description

12:15

12:45

12:45

2:30

2:30

2:40

2:40

3:15

3:15

4:00

4:00

4:15

Talk time 1015 minutes

Exercise time 45 minutes (Slide #46)
Teams of 5 document one real-time
process flow line from shop floor
Lunch
Process Flow Diagram Shop Floor Exercise
follow-up
Team preparation 45 minutes
Team presentations 30 minutes
Comparison 30 minutes
Process Flow Summary
Break
Overview of FMEA
What is a FMEA?
Describing the FMEA family
History and benefits
Key elements of an effective FMEA
Overview of PFMEA
What is a PFMEA?
PFMEA and APQP
Inputs/Tools
Outputs
Assumption and example
Wrap up

THE PIC GROUP

Reference
Material
form-Appx A)
Transparency
(blank PFD
form)

Format

Slides #47-49

Ppt

Slides # 50-59

Ppt

Slides # 60-67

Ppt

Slide #68

Ppt

ISSUE DATE: 31 MAY 04, REV #5

Instructor Guidelines GM-SI Flow, FMEA, Control Plans

Day 2
Start

End

8:30

8:50

8:50
9:35
10:00

9:35
10:00
10:15

10:15

11:10

11:10

11:30

Description
Objectives
Understand the PFMEA process sequence
PFMEA Stages and Phases
Walkthrough of the PFMEA form
Workshops step-by-step
Understand the PFMEA process sequence
PFMEA Stages and Phases
PFMEA Sample
Break
Understand PFMEA Header (columns 1-8)
Understand PFMEA Process
Function/Requirements (column 9)
Understand PFMEA Potential Failure Mode
(column 10)
Failure Mode examples (slide # 88)
Failure Mode types (slides # 89-92)
Understand PFMEA Potential Effect(s) of
Failure (column 11)
Understand PFMEA Severity (column 12)
Column review
Severity Evaluation Guidelines

Workshop (20 minutes)

Blank PFMEA form Appendix B
Have teams visit shop floor using PFMEA
form (blank) and fill out columns 1-12.

Reference
Material

Format

Slide # 69-72

Ppt

Slides # 73-83
Slides #84-85

Ppt
Ppt

Slides # 86-99

Ppt

Slide # 100
Transparency
(blank PFMEA
form Appx B)
Markers

Ppt

Slides # 101-104

Ppt

11:30

11:40

11:40

12:00

12:00

12:30

12:30

1:00

1:00

1:30

1:30

2:00

2:00

2:30

Understand PFMEA Classification (column

13)
Understand PFMEA Potential
Cause(s)/Mechanism(s) (column 14)
Understand PFMEA Occurrence (column 15)
Workshop (20 minutes)
Have teams revisit shop floor with using
PFMEA form (blank) and fill out columns 1315.
Use same transparency
Lunch
Understand PFMEA Current Process Controls
(column 16)
Prevention vs. Detection (controls)
Visual and Engineering controls
Error-proofing
Prevention vs. Detection (detection)
Understand PFMEA Detection (column 17)
PFMEA Detection Evaluation Guidelines
Understand PFMEA Risk Priority Number
(RPN) (column 18)
Workshop (20 minutes)

THE PIC GROUP

Slides # 105

Ppt

Slides # 106-110

Ppt

Slides # 111-114

Ppt

Slides # 115-119

Ppt

Slide # 120

Ppt

ISSUE DATE: 31 MAY 04, REV #5

Instructor Guidelines GM-SI Flow, FMEA, Control Plans

Start

End

Description

Reference
Material

Format

Slides # 121-125

Ppt

Slides # 126-149

Ppt

Slide # 150

Ppt

2:30

2:40

2:40

3:20

3:20

4:30

4:30

4:35

Have teams revisit shop floor using PFMEA

form (blank) and fill out columns 16-18.
Individual calculation of the RPN
Consensus on Detection.
Team calculation of the RPN
Break
Understand PFMEA Recommended Action(s)
(column 19)
Severity Example
Understand PFMEA Responsibility and Target
Date (column 20)
Understand PFMEA Actions Taken/Action
Results (columns 21-22)
PFMEA column summary
Ten Most Wanted problems with PFMEA
Quality objectives and PFMEA follow-up
Summary of PFMEA
Homework
Layered Audits
Master Dot
Wrap Up

THE PIC GROUP

ISSUE DATE: 31 MAY 04, REV #5

Instructor Guidelines GM-SI Flow, FMEA, Control Plans

Day 3
Start

8:30

End

Description

8:45

Objectives
Understand the Control Plan (PCP)
Walkthrough of the PCP form
In class exercise

8:45

9:30

9:30

9:40

9:40

11:10

Understand the Process Control Plan

Defining the PCP
Benefits of the PCP
Walkthrough of the PCP form
Control point / Check point / SPC
Quality Gates, Rework, other Visual
Controls
Break
In class PCP review activity
Use transparency to fill out PCP form that
is linked to PFD and PFMEA workshops.
Blank PCP form Appendix C
Have teams use their PFD and PFMEA
forms to fill in PCP form
Instructor will fill out transparency of form
based on answers from teams

11:10

12:10

12:10

12:40

12:40

2:30

2:30

2:40

2:40

3:00

3:00

3:30

3:30

4:00

4:00
4:15

4:15

Understand Standardized Work

Instructions
Review example

Lunch
PR/R Review
Next steps closing the gap
Break
Wrap up and Guidelines for Effective
PFMEA
Post-test
Review of objectives
In class team workshop follow-up exercise
(Discussion and flipchart)
Course evaluation
Adjourn and Appendix List

THE PIC GROUP

Reference
Material

Format

Slides # 151-155

Ppt

Slides # 156-170

Ppt

Slide # 172
Transparency of
blank PCP form
Blank PCP form
(Appx C)
Markers

Ppt
Transparency

Slides # 172-177
Transparency
(blank PFMEA
form)
Markers

Ppt

Slides # 178-179

Ppt

Slides # 180-182

Ppt

Slide # 183

Ppt

Slides # 184-185

Ppt

Slide # 186
Slides # 187

Ppt
Ppt

ISSUE DATE: 31 MAY 04, REV #5