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    Reaction Plan

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    MariaNilaZaragozaPalacio
    The document discusses reaction plans, mistake-proofing, and process control plans. It provides details on 5 types of reaction plans that can be considered when creating a process control plan. It also describes mistake-proofing methods used to eliminate defects by preventing or detecting mistakes. Finally, it outlines 10 key elements and 7 attributes of an effective process control plan, including monitoring inputs/outputs, setting control limits, and defining methods for monitoring, reacting to problems, and validating processes.

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    Reaction Plan

    Uploaded by

    MariaNilaZaragozaPalacio
    1K views14 pages
    The document discusses reaction plans, mistake-proofing, and process control plans. It provides details on 5 types of reaction plans that can be considered when creating a process control plan. It also describes mistake-proofing methods used to eliminate defects by preventing or detecting mistakes. Finally, it outlines 10 key elements and 7 attributes of an effective process control plan, including monitoring inputs/outputs, setting control limits, and defining methods for monitoring, reacting to problems, and validating processes.

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    The document discusses reaction plans, mistake-proofing, and process control plans. It provides details on 5 types of reaction plans that can be considered when creating a process control plan. It also describes mistake-proofing methods used to eliminate defects by preventing or detecting mistakes. Finally, it outlines 10 key elements and 7 attributes of an effective process control plan, including monitoring inputs/outputs, setting control limits, and defining methods for monitoring, reacting to problems, and validating processes.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    1K views14 pages

    Reaction Plan

    Uploaded by

    MariaNilaZaragozaPalacio
    The document discusses reaction plans, mistake-proofing, and process control plans. It provides details on 5 types of reaction plans that can be considered when creating a process control plan. It also describes mistake-proofing methods used to eliminate defects by preventing or detecting mistakes. Finally, it outlines 10 key elements and 7 attributes of an effective process control plan, including monitoring inputs/outputs, setting control limits, and defining methods for monitoring, reacting to problems, and validating processes.

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    Reaction Plan

    • Reaction Plan is the series of steps


    that you would take in response to
    a specified abnormal condition.
    • A reaction plan helps to minimize
    damage. It reduces the time
    between the occurrence of a
    problem and a stop gap.
    Reaction Plan
    There are 5 different types of reaction plans that
    can be considered while creating a process control
    plan:
    1. A plan to continue the process with close
    monitoring
    2. Enforce a manual override
    3. Follow special instructions
    4. Stop and escalate
    5. Stop, correct, and resume
    MISTAKE–PROOFING
    • Also called Poka-Yoke
    is a mistake proofing method that eliminates mistakes
    and defects, ensuring quality products and services. It originated
    from Japanese lean manufacturing.

    Awareness –Having a forethought that a mistake can be communicating


    the potential and planning the design of the product or process to detect
    or prevent it.

    Detection- Allowing the mistakes to happen but providing some means


    of detecting it and alerting someone so that we fix it before sending it to
    our customer.

    Prevention- Not allowing the possibility for the mistakes to occur in the
    first place
    When to Use Mistake–Proofing
    • When a process step has been identified where human error
    can cause mistakes or defects to occur, especially in processes
    that rely on the worker’s attention, skill or experience.
    • In a service process, where the customer can make an error
    which affects the output.
    • At a hand-off step in a process, when output or (for service
    processes) the customer is transferred to another worker.
    • When a minor error early in the process causes major
    problems later in the process.
    • When the consequences of an error are expensive or
    dangerous.
    Process Control Plan
    Control Plan - A Process Management tool used to identify and
    monitor the activities required to control the critical inputs and
    key outputs for a process, so the process will continually meet
    it’s product or service goals.

    10 Key Elements
    1. Risk Management
    2. Supplier Evaluation & Selection
    3. Contracts & Agreements
    4. Control Plan Methodology
    5. Product Acceptance Activities
    6. Supplier Performance & Monitoring
    7. Supplier Development
    8. Supplier Certification
    9. Change Control
    10.Supplier Corrective & Preventative Action
    Control Plan Attributes
    1. Process sequence
    2. Inputs/Outputs monitor
    3. Control limits for the process
    4. Method of monitoring/control
    5. Frequency of control
    6. Method of reaction to problems
    7. Validation/Qualification information
    Control Plan Attributes
    a. Process sequence
     List all steps used during the manufacturing process
     List all machines or tools used
    Control Plan Attributes
    2. Inputs/Outputs monitor
     Process inputs such as temp, time, speeds, feed rate
     Point to validations for process inputs
     List them individually on the CP
     Special processes (ex-passivation time & temp)
    Control Plan Attributes
    3. Control limits for the process
     List all critical features for the product being manufactured
    and the tolerance that is allowed for these features
     List acceptable ranges for process controls
    Control Plan Attributes
    4. Method of monitoring/control
     Define how the feature will be checked and how these
    checks are controlled (SPC, Validation, visual, etc)
     G R&R or MSA’s for inspection equipment can be listed
    here as well
    Control
    5. Frequency of control
    Plan Attributes
     How often will this dimension be inspected
     Capability must be established for a sampling plan to be in
    place
     The level of inspection should be related to the level of risk
    that is associated with the process or product
    characteristic
    Control Plan Attributes
    6. Method of reaction to problems
     Who is responsible for monitoring
     Procedure to follow if a defect is found
     MCDR, QC SOP#, segregate and reprocess, adjust tool, etc
    Control Plan Attributes
    7. Validation/Qualification information
     Actual protocol or document #’s for:
     All special processes must be validated
    THANK YOU!!! 

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