Interior Trim Retainer Clip

Seeded demo data

Control Plan · Injection Molding · Rev C

Part number: KMS-4417-02
Material: PA66-GF15
Process step: Injection Molding
Revision: C
Revised: 2026-07-24
Team: Process Engineering, Quality, Tooling

Controls

Change the method or the frequency on any of the 4 detection controls. Each one states the Detection ratings it can back, and the FMEA row linked to it is checked against that as you go.

6 controls across 4 rated causes

Characteristic	Specification	Evaluation Method	Sample	Control Method	Reaction Plan	Guards Against
CP-01 · product Snap-fit retention force Injection Molding Revised 18 Jun 2026	45 N minimum pull-out	Calibrated pull-force tester, lab cell Method	3 parts Frequency Supports D 9	Logged in the lab record, trend reviewed monthly	Quarantine back to the last passing test, notify process engineering, 100 percent pull test until capability is re-established	FM-01 Insufficient retention force FMEA out of date FM-01 carries D 7, this control supports D 9. Reconcile on the worksheet
CP-02 · process Pack pressure Injection Molding	620 bar +/- 25	Press controller readout Prevention control	Every cycle Continuous	Automatic alarm on out-of-band, press holds the cycle	Stop the press, isolate parts back to the last good reading, correct the setpoint before restart	FM-01 Insufficient retention force
CP-03 · product Retention barb width Injection Molding Revised 12 May 2026	3.20 mm +/- 0.10	Manual gauge check at the press Method	1 part Frequency Supports D 7 to 8	Recorded on the setup sheet	Sort back to the last good check, call tooling, verify cavity dimensions at the next service	FM-02 Retention barb oversized, clip will not seat in panel hole FMEA out of date FM-02 carries D 4, this control supports D 7. LowMedium Reconcile on the worksheet
CP-04 · product Parting line flash on the visible face Injection Molding	No flash above 0.15 mm	End-of-line vision check Method	100 percent Frequency Supports D 3 to 4	Automatic reject to chute	Segregate rejects, clean the tool at the next shift change, escalate to tooling above a 2 percent reject rate	FM-03 Flash at the parting line on the visible face
CP-05 · process Regrind ratio in the blend Material preparation Revised 02 Apr 2026	20 percent maximum	Blend recipe verified at the dryer Prevention control	1 per lot Every material lot	Blend sheet signed by the material handler	Hold the lot, re-blend to specification, impact test before release	FM-04 Clip embrittled, barb cracks in service
CP-06 · product Notched Izod impact strength Injection Molding	5.5 kJ/m2 minimum	Notched Izod impact test, off-line lab Method	1 part Frequency Supports D 5 to 6	Lab report filed against the lot number	Hold the lot, notify quality, review the regrind records for the affected blend	FM-04 Clip embrittled, barb cracks in service

Every control exists because of a rated cause on the process FMEA. The two documents are edited on different schedules, which is how they stop agreeing.

History

Every field-level change to either document, newest first, including anything changed in this session.

4 recorded changes

18 Jun 2026
CP-01sample frequency
1 per shift1 per week
Pull tester moved to the lab cell, shift sampling no longer staffed
Quality
12 May 2026
CP-03evaluation method
In-station vision system, suspect part locked outManual gauge check at the press
Vision cell removed during the line move, gauge check added as an interim control
Process Engineering
12 May 2026
CP-03sample frequency
Every cycle1 per hour
Manual check cannot run at cycle rate
Process Engineering
02 Apr 2026
CP-05specification
25 percent maximum20 percent maximum
Tightened after the Q1 brittleness containment
Materials

Controls flagged out of date are the ones whose linked FMEA row still carries a Detection rating the control cannot support. Editing changes this session only, and a reload restores the seeded documents.