En PLATO E1ns E-Learning - Lesson 4 - Methodology of Process Documents With Practical Example

E-Learning Course for PLATO e1ns
Lesson 4: Process methodology and

practical example
06.01.2021
1
Lesson 4, part 1:
Methodology of Process Documents:
Process Flow Chart (PFC) and
Control Plan (CP)
06.01.2021
2
Watch this lesson as a video
Online videos for lesson 4
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 – Methodology of Process Flow Chart and Control Plan

(in the video the following slides are explained in detail)
▪ Part 2 – Practical example for Process Flow Chart and Control Plan
(the video shows the practical example "live", without slides)
06.01.2021 © PLATO AG, e1ns Training
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Process Documents:
Process Flow Chart (PFC) and Control Plan (CP)
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Process Flow Chart (PFC)
Defining a Process Flow Chart - In table form
Module used: e1ns.methods – Process Flow Chart
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Defining a Process Flow in e1ns.flow - Graphically
Module used: e1ns.flow
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Control Plan (CP)
Definition of “Control Plan”
The production control plan contains all the necessary measures to optimally manage the
quality process in terms of the required quality and the costs to be met.
In particular, for all the interesting product characteristics, the control plan should
contain test methods and test tools to be used, the test frequency, the tolerances to be
maintained and the countermeasures to be initiated in the event of a deviation.
As a result, the production control plan fulfills both purposes:

complete and traceable documentation of quality control
06.01.2021 © PLATO AG, e1ns Prozess-FMEA
1.
2. Influence on quality and price of the final product
Compare Wikipedia: https://de.wikipedia.org/wiki/Qualit%C3%A4tsplanung

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e1ns.methods – Control Plan
Focus on the production process
▪ Control plan is required according to APQP and IATF 16949
▪ Fast creation on existing data from FMEA, Architect and Process Flow
▪ Product characteristics are automatically assigned to process steps
▪ Special characteristics are identified and controlled
Control Plan updates other documents: FMEA and Process Flow Chart
• Specifications
•
Ensures consistency of special characteristics through all documents
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e1ns.methods – Control Plan: Content of the table
Where do you What is inspected?

inspect? How do you react?
How do you test?
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e1ns.methods – Control Plan: Special Characteristics
Classification of special characteristics ▪ The classification of the

characteristics (product and process)
is based on findings of the FMEA and
external specifications.
▪ All characteristics with special
classification (e.g., BM S, CC, SC) must
be documented in a CP.
▪ All other characteristics can be

listed in a CP.
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e1ns.methods – Control Plan: Origin of data
Special process characteristics:

defined and specified in the
PFMEA
Process steps:
analyzed in PFMEA Machine-

FMEA
Special product characteristics:

defined and specified in the
DFMEA
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e1ns.methods – Control Plan: Product or Family
Product-CP
▪ The product-CP is created on a product system element
▪ It contains characteristics of a single product and it‘s processes
Family-CP
▪ The family-CP is created on a process system element

▪ It contains characteristics of all products of a family (e.g. left and right mirror)
▪ A structural design is necessary: 1 process is linked to n different products
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e1ns.methods – Control Plan: Product CP
Product
Product characteristics
DFMEA
Manufacturing
Process steps and characteristics
PFMEA / PFC
Machine A
Machine B Machines
Machine ...
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e1ns.methods – Control Plan: Family/Process CP
Product characteristics
Product 1 / DFMEA 1
Product 2 / DFMEA 2
Product 3 / DFMEA 3
Manufacturing 1-3
Process steps and characteristics
PFMEA / PFC
Machine A
Machine B Machines
Machine ...
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More on:
Special Characteristics
06.01.2021
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More on: Special Characteristics
Definition of „Special Characteristic“
Special Characteristics are product characteristics or production process characteristics that are
defined by the customer or the company itself.
IATF 16949 requires a marking if a characteristic has an impact on:
▪ Safety or compliance with official regulations
▪ Fit
▪ Function
▪ Performance
06.01.2021
▪ further processing of the product

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Definition of „Special Characteristic“
Special Characteristics defined by the customer must be documented and controlled by

the company and therefore be marked ...
▪ in the production control plan
▪ in drawings, the FMEA and operating instructions
by...
▪ a symbol from the customer
▪ a reference or symbol of the company
Special Characteristics must be consistent and traceable from the

06.01.2021
Design- and Process-FMEA to the Control Plan!

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Classification of Special Characteristics
The identification of the Special Characteristics in the FMEA is done by using

abbreviations:
For example, in Germany according to VDA:

▪ BM S (Sicherheit=safety)
▪ BM Z (Zulassung=legal)
▪ BM F (Funktion=functional)
▪ BM E Extern (external, by customer)
International:
▪ CC (Critical Characteristic)
▪ SC (Significant Characteristic)
06.01.2021
For companies that work with different customers, it is advisable to create a translation table.
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And now…
Let‘s jump one last time into the software and learn how to create process flow charts and
control plans!
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End of lesson 4, part 1
06.01.2021
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Lesson 4, part 2:
Practical exercise for
Process Flow Chart (PFC) and
Control Plan (CP)
06.01.2021
25
Watch this lesson as a video
Online videos for lesson 4
There are two videos available for this lesson. You can find both on the training content page
for this e-learning course:
▪ Part 1 – Methodology of Process Flow Chart and Control Plan

(in the video the following slides are explained in detail)
▪ Part 2 – Practical example for Process Flow Chart and Control Plan
(the video shows the practical example "live", without slides)
The following applies to this lesson as well:

The next exercises are explained in detail in the accompanying video. You can play it and work
on your training environment at the same time.
If you would like it to be a little more challenging, then just try to do the exercises on your own
first!
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Exercise 12: e1ns.flow – Graphic Process Flow Chart
Create a graphic Process Flow Chart for "Final assembly pen"
▪ Switch to module e1ns.flow
▪ Map the existing process steps on the drawing and connect them logically
▪ Enter a suitable symbol for the respective type of process step
▪ Number the steps

06.01.2021 © PLATO AG, Training exercises
▪ Add a new step “Rejects” after the existing step “Functional check”.
▪ Label the connecting arrows with "OK" and "NOK".
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Exercise 12: e1ns.flow – Graphic Process Flow Chart
▪ Solution:
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Exercise 13: e1ns.methods – Process Flow Chart
Create a tabular process flow chart for "Final assembly pen"
Switch to e1ns.methods > Manufacturing > Process Configurator

▪ Remove any steps marked red and marked for deletion. These are "leftovers" from working
in e1ns.flow.
Switch to e1ns.methods > Manufacturing > Process Flow Chart

▪ All steps are already entered, because the sequence was taken from e1ns.flow!
▪ Manually add further process steps in the table.
▪ Check the symbols for the process type.

▪ Check the entries in the columns "Preceding Steps" and “Subsequent Steps".
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Exercise 13: e1ns.methods – Process Flow Chart
▪ Solution
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Exercise 14: e1ns.methods – Control Plan
Create a Control Plan for "Final assembly pen"
Switch to e1ns.methods > Manufacturing > Process Configurator

▪ Select all steps (except “Rejects" and "Transport to warehouse") to be listed in the Control
Plan
▪ Assign the specifications from Design and Process elements to the respective process steps
Question: „Which characteristic is influenced by which step?“
Switch to e1ns.methods > Manufacturing > Control Plan

▪ Complete the table for the process characteristic “Assembly pressure"
e.g.: pressure sensor, 100%, constant, maintenance protocol, document xyz
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Exercise 14: e1ns.methods – Control Plan
▪ Solution
Note: These product characteristics are not very suitable for inclusion in the CP. So please just look at it as an example or create a separate CP for
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the production of the refill!
Quiz for lesson 4
Online self-test
▪ Click here to start a quiz for lesson 4. Good luck!

06.01.2021
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Feedback Form
We would be very pleased to receive feedback on this e-learning course.
Please use the online questionnaire behind this hyperlink (click on underlined text).
Thank you!
06.01.2021
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End of lesson 4
... end of this E-Learning Course
06.01.2021
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One more thing…
06.01.2021
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Repetition by Video Tutorial
Video Tutorial
Follow this link to open our PLATO video platform. It contains a series of 7 Youtube videos
which you can use to repeat all the topics of our training sessions.
▪ https://www.plato-e1ns.com/about-plato/press-service/video-portal/plato-e1ns-
software-and-methods/
37

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E-Learning Course for PLATO e1ns

Lesson 4: Process methodology and

▪ Part 1 – Methodology of Process Flow Chart and Control Plan

As a result, the production control plan fulfills both purposes:

Compare Wikipedia: https://de.wikipedia.org/wiki/Qualit%C3%A4tsplanung

Ensures consistency of special characteristics through all documents

Where do you What is inspected?

Classification of special characteristics ▪ The classification of the

▪ All other characteristics can be

Special process characteristics:

analyzed in PFMEA Machine-

Special product characteristics:

▪ The family-CP is created on a process system element

IATF 16949 requires a marking if a characteristic has an impact on:

▪ Safety or compliance with official regulations

▪ further processing of the product

Special Characteristics defined by the customer must be documented and controlled by

▪ in the production control plan

▪ in drawings, the FMEA and operating instructions

▪ a symbol from the customer

▪ a reference or symbol of the company

Special Characteristics must be consistent and traceable from the

Design- and Process-FMEA to the Control Plan!

The identification of the Special Characteristics in the FMEA is done by using

For example, in Germany according to VDA:

▪ Part 1 – Methodology of Process Flow Chart and Control Plan

The following applies to this lesson as well:

Create a graphic Process Flow Chart for "Final assembly pen"

▪ Switch to module e1ns.flow

▪ Enter a suitable symbol for the respective type of process step

▪ Number the steps

▪ Label the connecting arrows with "OK" and "NOK".

Create a tabular process flow chart for "Final assembly pen"

Switch to e1ns.methods > Manufacturing > Process Configurator

Switch to e1ns.methods > Manufacturing > Process Flow Chart

▪ Check the symbols for the process type.

Create a Control Plan for "Final assembly pen"

Switch to e1ns.methods > Manufacturing > Process Configurator

Switch to e1ns.methods > Manufacturing > Control Plan

e.g.: pressure sensor, 100%, constant, maintenance protocol, document xyz

▪ Click here to start a quiz for lesson 4. Good luck!

We would be very pleased to receive feedback on this e-learning course.

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