PCCI_PP_Slides_Industry.pdf

Process Capability, Control, and Improvement (PCCI) Clause

Execution of the Clause for Industry

Overview

• What is the PCCI Clause?

– Alternative to the SPC Clause

• The Government seeks to buy conforming product produced with capable processes

– LAT sampling is merely detection, we’re after prevention as well

Goal of PCCI

• Focus on controlling the most important characteristics: Characteristics for Process Control (CFPCs)

– Quality, like everything, is a resource

• Get away from attributes

• Move towards acceptance based on process control

Deliverables

• Process Control Plan

– Initial: due 60 days after contract award

– Subsequent: due 60 days prior to First Article Testing (FAT) or production if FAT is not required

Execution Roadmap

Process Flow Chart

• ISO 5807 has some guidance on flow chart symbols

Start Forging Final Machining

1.2 1.3

End Heat

Treatment

•Vendor -supplied steel

•Certificate of Conformance

•Forging dies

GHI -789

•Tensile tester

GHI -790

•Non -destructive tester GHI -791

•Forge -ready part

•Structurally compliant part

•Rough -shape configuration

•Physically compliant part

•Batch furnace 3 •Furnace “recipe”

ABC -123

•Furnace

SOP DEF -456

1.1

•Hydraulic press •Forging “recipe” ABC - •Forging per

SOP DEF -457

•Mechanical Properties test per SOP DEF -458 •Non - Destructive testing per SOP

DEF -459

•Machining cell 1 •Machining per

SOP DEF -459

External contour Maximum outside diameter (Bourrelet )

Body Joint threads

•Dimensional inspection per SOP

DEF -460

•Wall thickness measurement per

SOP DEF -461

Protective Coating

1.4

•TDP compliant part

•Coating cell 2 •Corrosion protective coating per SOP DEF -462 •Painting cell 1 •Corrosion protective coating per SOP DEF -463

•Commercial standard gaging

•Special wall thickness tester

GHI -792

•Coating fixture

GHI -793

•Painting fixture

GHI -794

Characteristics for Process Control

• Characteristics for process control are features within a product, subassembly, part and process whose variation from nominal (i.e., target value) significantly impacts safety, performance in terms of customer’s requirements, or final cost of a product.

Special controls should be applied where the cost of variation justifies the cost of control.

CFPCs

CFPCs and Critical Characteristics

• The Critical Characteristic Clause (CCC) is the primary vehicle for controlling Criticals (if present in the contract)

• The PCCI clause can help lower the Non- Conforming Material rate for the CCC

• Some overlap expected between the two lists, but not all Criticals have to be CFPCs

Initial PCP

• What must the plan contain? Information on:

– Manufacturing

– Inspection

– Material Handling

– Initial/Proposed Control method

– Action Plan

– Initial Capability

Process Failure Modes and Effects Analysis (PFMEA)

USG provided requirements and classifications, completed by the Contractor

Example PFMEA

References include SAE ARP 5580, SAE J1739, AIAG Potential FMEA

FM # Function Requirement Potential Failure Mode

Potential Failure Effect

S E V Classification

Potential Causes of Failure

Controls Prevention

O C C

Controls Detection

D E T

R P N Responsible, actions, etc.

1 Projectile penetration 3.3.1 Penetration hardness too high Projectile breakup 6 Major

Poor heat treat -too long Time lock 1

SPC for hardness 3 18

2 hardness too low Projectile breakup 6 Major Poor heat treat -too short Time lock 1

SPC for hardness 3 18

Poor heat treat -uneven none 3

SPC for hardness 3 54

Heat gradient study Non-destructive detection

- Rosie

3 velocity too low Projectile breakup 6 Major Low propellant Fill-pro 1

High speed check-weigh 1 6

DFMEA Template.xls

PCP Example

• Primary document is a table (Excel template provided)

– Expand on Control Method and Action plan with text

Part Name/Description: Bullet Organization/Department: Metal parts

Drawing Number/Rev: 123456789

CFPC Classification process/operation machine/device/tool requirement inspection technique/AIE sample capability control method action plan

Poor heat treat -uneven Major 2.1.1 Heat Treat Furnace Rockwell C 44-48 Hardness tester #485662 3/batch See 1.1 See 2.1

PCP Control Method & Action Plan

1.0 Control Methods

1.1 Only use approved rack for treating parts. Rack must

be full before treating a batch. Posts colored bright orange for mistake proofing. Furnace on a time lock to prevent opening and associated heat loss. Use SPC on hardness.

2.0 Action Plans

2.1 If SPC indicates process drift per run rules 1, 2, 4 & 5, disposition the batch per SOP-1234. Operator shall contact Maintenance to perform Maintenance Procedure MP-5678 and fill out Re-Start Checklist XYZ for records.

Attributes Data

• Not ideal

• Try to go upstream

• Mistake-proof

• 100% inspect

• For operator (manual) processes, use the PFMEA to identify possible failure modes and mistake proof them as part of the control plan.

• This clause does not mandate SPC, so contractors are encouraged to find the method of process control that best suits the process.

Data Quality

• “Decisions are no better than the data on which they are based” Juran’s Quality Handbook

• How do you know your data is worthwhile?

Measurement System Analysis

(MSA)

• Stability

– Does the Measurement System give the same results over time?

– Xbar R chart

• Bias

– Does the Measurement System over- or under-read the part?

– Histogram

• Linearity

– Is the Bias the same across the part tolerance?

– Graph: Reference Value vs. Bias

• Repeatability & Reproducibility

– Does the Operator affect the results?

– ANOVA

MSA References

• AIAG: Measurement Systems Analysis

• ASTM: E2782 – 10 Standard Guide for Measurement

Systems Analysis

• ASME: - PTC 19.1 – 2005 Test Uncertainty

- B89.7.2 – 1999 Dimensional

- Measurement Planning

- Specific Measurement & Metrology

• NIST: Esoteric Measurement & Metrology (e.g.

Simultaneous Measurement of Magnetic Vortex Polarity and Chirality using Scanning Electron Microscopy with Polarization Analysis (SEMPA))

Stability/Capability Analysis

• Manage the process, not the measurement

• Process must be Stable (in statistical control) before a Capability Analysis can be performed

• Special causes of variation must be eliminated

• Then the performance becomes predictable, and its capability of meeting the requirement can be assessed.

Revised PCP

• Validate the Characteristics for Process Control

– Further determine what needs to be controlled

• Include Capability at rate

CFPC

Classificatio n process/operatio n machine/device/tool requirement inspection technique/AIEsample capability control method action plan

Poor heat treat -uneven Major 2.1.1 Heat Treat Fan 360 - 380 RPMs DAQ system

Every 5 minutes 4.28See 1.1 See 2.1

2.1.1 Heat Treat Power supply 1000 - 1100W DAQ system

Every 5 minutes 6.1See 1.2 See 2.2

2.1.1 Heat Treat Thermocouple 1 555-560F DAQ system

Every 5 minutes 3.67See 1.3 See 2.3

2.1.1 Heat Treat Thermocouple 2 545-550F DAQ system

Every 5 minutes 3.54See 1.4 See 2.4

Sub-tier Suppliers

• Only involved if their processes can affect CFPCs

• Encouraged to be part of the joint USG-Industry team

– Special scenarios could dictate direct communication between the sub-tier supplier and the USG

• Each facility can have its own PCP

– Prime contractor still responsible for control of CFPCs

Alternate Acceptance

• Based on process control and what is laid out in the PCP

• Alternate acceptance: Conformance vs.

performance

• Alternate Acceptance for Criticals?

CARs & RFVs

• Triggers reevaluation of the list of CFPCs and the PCP

– Are new CFPCs required?

– Are new control methods required for existing CFPCs?

Communication

• Formal submittal and approval required for the initial and the subsequent PCP

– Sent through the PCO

• Technical activities conducted face to face (ideal) or via telecon

• Notification that minimum process capability levels are not being maintained is to local USG representative (DCMA/QAR)

Questions?