W10343440 PDF

Document
Type: ENGINEERING P ROCEDURE Document

Number
Description PROCEDURE – SP ECI AL
(English) W10343440
CHARACTERISTI CS
Description Revision
(Local) C
Whirlpool Corporation, Benton Harbor, MI, USA
1. PURPOSE
The purpose of this procedure is to define how potential risk items for new products within Whirlpool Corporation
are identified and transferred to appropriat e processes. Adherence to this procedure will ensure potential risk items
are communicated and understood by appropriate levels within the organization. In addition, this procedure
provides a listing of items to be addressed in the Continuous Improvement Process.
2. SCOPE
GEOGRAPHIC:
Place an “x” in the appropriate boxes
EMEA ME X WOC Global X
LAR NAR WOI
ORGA NIZA TIONAL:

Place an “x” in the appropriate boxes
Air Treatment Food Preparation Refrigeration

Cleaning Microwave Storage Organization
Cont rols & Electronics Other Products & Servic es Water Products
Fabric Care Portable Appliances Cooling Solutions Tech.
All Product Groups X Trash Compactor
APPLIES TO: All engineering drawings
3. REFERENCES
W10675750 SPECIFICA TION – SPECIAL CHA RACTERS TICS
W10423722 Failure Mode and Effects Analysis (FMEA) Work Instructions
4. TERMS, DEFINITIONS, ABBREVIATIONS, AND ACRONYMS

TERM DEFINITION
Specifies a series of operations or actions which have to be executed in the same manner
in order to obtain the same result under the same circumstances. The procedure is a
Engineering Procedure sequence of processes, activities, steps, tasks, decisions, or calculations that when done
in the sequence established by the proc edure, produces the described result, product or
outcome.
A Product or Process characteristic for which reasonably anticipated variation could potentially
affect a product’s safety or compliance with regulatory requirements, or could potentially affect
Special Characteristics customer satisfaction with a product. Special Characteristics are “boated” in the applicable product,
process documentation. Special characteristics are denoted as Critical Characteristics or high
impact characteristics.
Created This document is the property of Whirlpool Corporation. It contains confidential

By WILLIJN information belonging to and/or entrusted to Whirlpool. It is disclosed in confidence
and shall not be held, reproduced, disclosed or used except in a manner and for a Page
purpose expressly permitted by Whirlpool in writing. 1 of 12
Creation
Date 14-JAN-2014 Vendors shall not revise any physic al, dimensional, or performance characteristics
unless authorized in writing by this Whirlpool engineering group.
Source Document: W10335242 Rev D
In some European factories the letter "W" of the part code mentioned herein will be automatically
04-Mar-2014 09:25:10 EST | RELEASED replaced by the number "4000" (e.g. "W12345678" becomes "400012345678")
Document
Number
(English) W10343440
CHARACTERISTI CS
(Local) C
TERM DEFINITION
A Product or Process FMEA line item is assigned a CC for which reasonably anticipated variation
Critical Characteristic could potentially affect a product’s safety, compliance with regulatory requirements, or DOE
“CC” standards.
Tied to Severity = 9 issues.
A Product or Process FMEA line item is assigned a HIC for which reasonably anticipated variation
High Impact could potentially affect customer satisfaction with a product.
Characteristic “HIC” Tied to Severity = 5 – 7 levels.
A characteristic (usually a dimension) that is part of a variation chain (stack up). If the dimensional
Medium Impact variation exceeds the defined capability, there can be a negative impact on fit, function, durability,
Characteristic “MIC” customer satisfaction (including internal customers), assembly, or manufacturability.
When a characteristic is jointly owned by two responsibilities, we refer to each group as having a
risk partner. To qualify as having a risk partner, one or more responsibilities must be shared by the
two risk partners (i.e. engineering design, preventive control, or detective control). Both risk
partners must document their own responsibility and clerically point to the risk partner’s
responsibility in the Recommended Action & Responsibility column of the FMEA. This is commonly
called the document linkage reference and must be contained in each risk partners FMEA to be
complete.
Risk Partner If a characteristic is noted in a Subsystem FMEA and the design and controls are wholly owned by
our company, then a corresponding characteristic may be driven down to the Module Variant FMEA
if it is relevant.
If the characteristic IS to be contained in the Module Variant FMEA (wholly or jointly owned), it must
be embedded in the applicable component design, process and supplier records.
If the characteristic is generated at the process level (wholly owned), it must be embedded in the
applicable process generated records.
Means that a group has full responsibility for the design, preventive control(s), and detective
Wholly owned control(s).
The Capability Ratio, Cp, is an index number that compares the specified tolerance with the process
potential.
𝑈𝑈𝑈𝑈𝑈𝑈 −𝐿𝐿𝐿𝐿𝐿𝐿 𝑅𝑅� ��
𝑀𝑀𝑀𝑀
𝐶𝐶𝑝𝑝 = 6𝜎𝜎�
Where 𝜎𝜎� = or 𝜎𝜎� =
𝑑𝑑 2 𝑑𝑑 2
Cp Calculated from a process that exhibits a state of statistical control. Cp represents a best case
(Capability Ratio) value indicating how good the process could be if the process were centered and operated in a state
of statistical control.

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TERM DEFINITION
The Centered Capability Ratio, Cpk, expands on Cp by taking into account how centered the
process is within the specification limits.
𝑋𝑋� − 𝐿𝐿𝐿𝐿𝐿𝐿 𝑈𝑈𝑈𝑈𝑈𝑈 − 𝑋𝑋�

𝐶𝐶𝑝𝑝𝑝𝑝 = 𝑀𝑀𝑀𝑀𝑀𝑀 � , �
3𝜎𝜎� 3𝜎𝜎�
Cpk 𝑅𝑅� ��

𝑀𝑀𝑀𝑀
Where 𝜎𝜎� = or 𝜎𝜎� = calculated from a process that exhibits a state of statistical control.
(Centered Capability 𝑑𝑑 2 𝑑𝑑 2
Ratio)
When a process is operated at the mid-point of the specifications Cpk will be equal to Cp. As the
process average deviates from mid-point of the specifications Cpk will be smaller than Cp. Hence, it
is not the size of Cpk, but rather the size of Cpk relative to Cp that will characterize how well-
centered the process is.
The Performance Ratio, Pp, compares the specified tolerance with Past Process Performance. This
ratio serves no purpose in the prediction of future performance of a process and should only be
used to characterize historical performance.
𝑈𝑈𝑈𝑈𝑈𝑈 −𝐿𝐿𝐿𝐿𝐿𝐿
𝑃𝑃𝑝𝑝 = 6𝑠𝑠
Where s is the Global Standard Deviation Statistic calculated as follows:
Pp
𝑛𝑛
(Performance Ratio) (𝑥𝑥𝑖𝑖 − 𝑥𝑥̅ )2
𝑠𝑠 = ��
𝑛𝑛 − 1
𝑖𝑖 =1
If the process has historically been operated in a state of statistical control then Pp ≈ Cp.
Differences in Pp and Cp show the effect of past process instabilities on past process performance.
Since Pp is a measure of historical performance in general sufficient data exists that the calculation
of a confidence interval around s is not required.
The Centered Performance Ratio, Ppk, expands on Pp by taking into account how centered the
process is within the specification limits. This ratio serves no purpose in the prediction of future
performance of a process and should only be used to characterize historical performance.
𝑋𝑋� − 𝐿𝐿𝐿𝐿𝐿𝐿 𝑈𝑈𝑈𝑈𝑈𝑈 − 𝑋𝑋�

Ppk 𝑃𝑃𝑝𝑝𝑝𝑝 = 𝑀𝑀𝑀𝑀𝑀𝑀 � , �
3𝑠𝑠 3𝑠𝑠
(Centered
Performance Ratio) Where s is the Global Standard Deviation Statistic calculated as shown above (See Pp).
If the process has historically been operated in a state of statistical control then Ppk ≈ Cpk.
Differences in Ppk and Cpk show the effect of past process instabilities on past process
performance. Since Ppk is a measure of historical performance in general sufficient data exists that
the calculation of a confidence interval around s is not required.
For the complete listing of all current Engineering Terms & Definitions, please visit:
http://engtech.whirlpool.com/globalengstds/engineering-terms-definitions/

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5. PROCEDURE
Input Requirements: Input Requirements: See Input Requirements: See

Controlled experimentation, bullet 1 in Risk partner bullet 2 in Risk partner
tolerance stacks, sources of def inition. def inition.
v ariation identif ication, and
other techniques. Also can
include historical FMEA
inf ormation, f ield SIR
inf ormation, historical liability
inf ormation, and subject
matter experts.
1.0 Special Characteristics 2.0 Special Characteristics 3.1 Producibility Review:

identified in Platform or finalized in Subystem Special Characteristics
Subsystem FME A or from FME As and transferred finalized in Module Variant
historical experience from Subsystem FME A to FME As and transferred
Module Variant FME As from Module Variant
FME As to Drawings and
technical specifications
Tools used to accomplish Tools used to accomplish Tools used to accomplish

task: Ontrac, W10675750 task: FMEA f orm task:
assignment criteria Producibility Team Rev iew Engineeri ng release process
Meeting Minutes Producibility Team Rev iew
Meeting Minutes
Input Requirements: See Input Requirements: See Input Requirements:

bullet 2 in risk partner bullet 2 in risk partner Completion of step 4
def inition, Engineering def inition, Engineering
release process Release process
3.2 Producibility Review: 4.0 Special Characteristics 5.0 Assess Manufacturing,

Special Characteristics transferred from Supplier capability and
transferred from Module Manufacturing, Supplier develop ongoing sampling
variant FME As to Process FME As to Work strategy, inspection plans,
Manufacturing, Supplier Instructions, Control Plans and improvement plans
Design and Process FME As
Tools used to accomplish Tools used to accomplish Tools used to accomplish

task: FMEA f orm task: FMEA f orm task: Ref erence section 10
Producibility Team Rev iew Control Plan Form
Meeting Minutes Work Instruction Form
Note: Producibility reviews and finalized special characteris tics and control plans finalized prior to Technic al Feasibility Event (TFE)

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6. RESPONSIBILITIES MATRIX
Function / Title
1 2 3.1 3.2 4 5
Platform Owner A
Subsystem Owners R.A
Module Owner A A I
Release Engineer R,A R,A R,A I
Project Technical Lead C A A
Project Quality Lead A A I
Code s and Safety C,A CA I
Supplier Development
C,A C,R,A I R,A
Engineer
Supplier C,A C,I,A R,A R,A
Manufacturing C,A C,A C,I,A R,A R,A
R = responsible for execution C =consulted for execution ( ) = as necessary

A = accountable (approve) I = informed of execution
7. SPECIAL CHARACTERISTICS FLOW IN DOCUMENTATION
Platform Subsystem Drawings & Mfg. and Supplier

FMEAs FMEAs Specifications PFMEAs
Control Plans Work Instructions

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8. OVERVIEW OF SUGGESTED IMPLEMENTATION

Appl y project FMEA methods and develop
Platfor m Subs ystem DFMEA Subs ystem Platfor m project actions to reduce criticality
Requirements Design Specs Design Specs Requirements
Validated Potential Potential Others
Critical High Impac t
DFME A Description Criteria Required Action

Classification
Project iteration
CC Critical Characteristic: Sev erity = 9 Use process
and optimization Appl y process FMEA methods and develop
Potentially affects control (SPC)
project/process actions to reduce criticality
saf ety and/or and prov e that
standards compliance Cpk complies
Potential Potential Others
with the
Critical High Impac t
requirements
HIC High Impact Sev erity 5 Use process
Characteristic: or 7 control (SPC)
Potentially affects and prov e that
customer satisf action Cpk complies
with the
requirements
Blank Not identif ied as Sev erity < 5 Control
critical aff ectiv ely as
appropriate
Can the
CC identified on the Yes Is the
characteristic be
drawi ng Drawing shown on a associate
component DFMEA
Confirm CCs
failure mode
CC drawi ng or is it the
result of a severity = 9?
stac kup?
No
Stac kup
MIC identified on the

drawi ng Execute stac kup and
identify components of
variation
Resulting Cpk must be
MIC ≥ 2

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Can the
HIC identifi ed on the characteristic be If the severity Yes Is the
Drawing
drawi ng shown on a =5, is the associate
component Confirm HICs occurrenc e DFMEA failure
mode s everity
HIC drawi ng or is it the
result of a
≥ 5?
= 5 or 7?
stac kup? Yes
No No
Not a s pecial
Stac kup characteristic
MIC identified on the

drawi ng Execute stac kup and
identify components of
variation
Resulting Cpk must be
MIC ≥ 1.67
Note: The decision to classify an object as special
requires engineering judgement.
The FMEA severities of failure modes that are
mapped into a characteristic, the percent
contribution to each failure mode, and the total
number of failure modes must be considered.
Control Pl an: Includes
CC/HIC/MIC and
quality c harac teristics
based on process data Monitor/Control
and capability. Processes

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9. GENERAL ACCEPTANCE CRITERIA

See W10675750 Specification – Special Characteristics
10. ACTION TO BE TAKEN

If a given process does not deliver the required Cpk the following actions can be taken in this order of priority:
1. increase characteristic tolerance
2. to reduce process variation
3. 100% inspection, when it is not possible to do 1 or 2
11. CONTROL PLAN

No documented standard
12. INITIAL PROCESS STUDY

• Initial process studies are short-term and will not predict the effects of time and variation in people,
materials, methods, equipment, measurement systems, and environment. Even for these short-term
studies, it is important to collect and analyze the data in the order produced using control charts.
• The initial process study results are dependent on the purpos e of the study, method of data acquisition,
sampling, amount of data, demonstration of statistical control, etc.
• The purpose of the initial process study is to understand the process variation, not just to achieve a
specific index value.
• Unstable processes: depending on the nature of the instability, an unstable process may not meet
process requirements. The organization shall identify, evaluate, and eliminate special causes of
variation prior to process evaluation.
13. CONSIDERATIONS FOR RATIONAL SUBGROUPING AND SAMPLING

STRATEGY
• To estimate a process Cpk, the process variation must be in state of statistic control. This applies to
either within or bet ween subgroups variation
• “In control” is defined by absenc e of special causes, shifts or drifts in the process
• If a part is produced by different molds, cavities, machines, etc, (simultaneously or not) the systematic
effects must be noted and the Cpk calculations must consider it.

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• For example: If two machines produce a plastic part at the same time, they might produce two
independent proc esses, with own means and variances. A Cpk must be calculated for each one and
evaluated separately
• The data must be collected across the sources of variation that will be present in the ongoing
production. Random sampling does not provide context to the data. Process mapping is recommended
to promote critical thought and understating of the process.
• It is good practice to subgroup sources of variation that have similar rat es of change in the process.
• Example of sampling plan on an injection molding process
Lot Material 1 2 3
Machine 1 2 1 2 1 2
Mold 1 2 1 2 1 2 1 2 1 2 1 2
Part 123 456………
• Crossed studies might produce systematic effects due to interactions.
• Cpk is heavily dependent on the specification definition. Specs must represent functional limits of the
product, considering the variety of stresses that the product may be submitted. These limits must be
proved with data from, for example, experimental data.
14. SEVERITY RANKING FOR PRODUCTS

Referenc e W10423722 Failure Mode and Effects Analysis (FMEA) Work Instructions
15. OCCURRENCE RANKING FOR PRODUCTS

Referenc e W10423722 Failure Mode and Effects Analysis (FMEA) Work Instructions
16. POTENTIAL VS. CONFIRMED SPECIAL CHARACTERISTICS

A Design FMEA indicat es potential Critical Characteristics and pot ential High Impact Special Characteristics that
affect product . Where applic able, they are transferred to the process and supplier FMEAs.
A Process FMEA indicates potential Critical Characteristics and potential High Impact Special Characteristics that
affect product and process .
Confirm ed CC and HIC characteri stics are those that are support ed by factual test, SIR, simulation or non-
capability to requirements. They are confirmed only after all design/process alternatives are exhausted and when
necessary associated special controls are identified or safety sign-off is required.
All Special Characteristics are to be reviewed in a producibility review.
Critical characteristics require a safety review.

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16.1 Confirmation of a Special Characteristic:

• The D/PFMEA process raises potential failure modes and Special Characteristics may be correlated
• To confirm Special Characteristics, factual tests, as design for experiments, safety evaluations,
reliability tests, test to failure, etc must be performed.
• Special characteristics and their limits must be defined as per functional limits of the product over the
variety of stresses
• The variety and distribution of stresses must be considered regarding consumer use, installation,
transportation, and manufacturing. This information must be used to design the tests to
validate/invalidate Special Characteristics.
• A confirmed Critical Characteristic (CC) is noted on a drawing with a boat displaying “CC” in the interior
• A confirmed High Impact Characteristic (HIC) is noted on a drawing with a boat displaying “HIC” in the
interior
16.2 Correlation between Special Characteristics:

• For HICs with associated severities equal to 5, correlations between characteristics can be applied. This will
reduce the number of Special Characteristics that require special controls
• If two or more HICs are correlated, the part owner can decide to denote the characteristic for one (or less
than all) of them since
o There are engineering reasons to consider it (physics)
o The characteristics are correlat ed. In this case the correlation coefficient must be at least 0,8,
where the correlation coefficient is denoted by r and defined by:
2
𝑠𝑠𝑥𝑥𝑥𝑥 ∑ 𝑤𝑤𝑖𝑖 ( 𝑥𝑥 𝑖𝑖 − 𝑥𝑥�𝑖𝑖 )(𝑦𝑦𝑖𝑖 − 𝑦𝑦�)
𝑖𝑖
2
𝑟𝑟𝑥𝑥𝑥𝑥 = 𝑤𝑤ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑠𝑠𝑥𝑥𝑥𝑥 =
�𝑠𝑠𝑥𝑥2 𝑠𝑠𝑦𝑦2 𝑑𝑑𝑑𝑑
16.3 Options for removal of Design Critical Characteristics:

• Product Redesign that demonstrates a revised level of the severity.
• Where Design Guideline exists, has been reviewed, has been demonstrated to resolve issues. Example:
Materials requirement for toxicity.
• Where Safety defines as unreasonable and has provided signature approval for removal OR
• Where addressed currently in Hazard Database and existing controls will be maint ained.

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16.4 Options for removal of Process only Critical Characteristics:

• Process Redesign that demonstrates a revised level of the severity.
• Where Process Guideline/procedure exists, has been reviewed, has been demonstrated to resolve issues.
Example: Lockout/ Tagout, special shielding,…...
• Where Plant Safety defines as unreasonable and has provided signature approval for removal OR
• Where addressed currently in Hazard Database and existing controls will be maint ained.
16.5 Options for removal of Design High Impact Characteristics:

• Product Redesign that demonstrates a revised level of occurrence and improves robustness against the
applicable environment al, parametric and load variables over product life.
16.6 Options for removal of Process only High Impact Characteristics:

• Process Redesign that demonstrates a revised level of occurrence / Cpk and improves robustness
against the applicable process environmental, parametric, load and human factors variables over the long
term process.
NOTE: A Process FMEA determines (via capability studies) the level of control required and the
implementation of Special Controls.
17. Producibility review for Special Characteristics

Actions and Decision Rules:
• A review of Potential vs. Confirmed Special Characteristics.
• Where deemed confirmed, transfer from FMEA to print and part via boated dimension.
• Under no circumstances is “Life of Tool” to be granted for a boat ed dimension.
• Removal or addition of a boated dimension requires a decision tree based on FMEA and communication via
the producability review.
• Where capabilities are not being met (process and/or supplier), a short term and long term action plan is
required to transition us to reach compliance. A functional part of the plan is to audit control plan elements to
assess on-going growth towards compliance.

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CONTRI BUTORS
(Individuals who contributed to the content of this document)
NAME USERID NAME USERID
Bardal, Alex BARDAAM Sharp, Brenner SHARPB
Johnson, Roger JOHNS RF Senger, Fernando SENGEFC
Lawrence, Andrew LAWREAS Williams, Jeff WILLIJN
Rieger, Tobias RIE GE T
REVISION HISTORY
REV DESCRIPTION OF CHANGE SECTION BY E. N. DATE
A Released --- JOHNS RF 646277 07 MAR 2011
B Revised cont ent for consistency 4, 9 JOHNS RF 647100 15 MAR 2011
Redrawn to new template
Added MIC Medium Impact Characteristic
C 8 WILLIJN 753987 17 JA N 2014
Reloc ated section 10 to new Specification
10
W10675750

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Document

Type: ENGINEERING P ROCEDURE Document

EMEA ME X WOC Global X

LAR NAR WOI

ORGA NIZA TIONAL:

Air Treatment Food Preparation Refrigeration

APPLIES TO: All engineering drawings

4. TERMS, DEFINITIONS, ABBREVIATIONS, AND ACRONYMS

Created This document is the property of Whirlpool Corporation. It contains confidential

Created This document is the property of Whirlpool Corporation. It contains confidential

𝑋𝑋� − 𝐿𝐿𝐿𝐿𝐿𝐿 𝑈𝑈𝑈𝑈𝑈𝑈 − 𝑋𝑋�

Cpk 𝑅𝑅� �����

Where s is the Global Standard Deviation Statistic calculated as follows:

𝑋𝑋� − 𝐿𝐿𝐿𝐿𝐿𝐿 𝑈𝑈𝑈𝑈𝑈𝑈 − 𝑋𝑋�

Created This document is the property of Whirlpool Corporation. It contains confidential

Input Requirements: Input Requirements: See Input Requirements: See

1.0 Special Characteristics 2.0 Special Characteristics 3.1 Producibility Review:

Tools used to accomplish Tools used to accomplish Tools used to accomplish

Input Requirements: See Input Requirements: See Input Requirements:

3.2 Producibility Review: 4.0 Special Characteristics 5.0 Assess Manufacturing,

Tools used to accomplish Tools used to accomplish Tools used to accomplish

Created This document is the property of Whirlpool Corporation. It contains confidential

R = responsible for execution C =consulted for execution ( ) = as necessary

7. SPECIAL CHARACTERISTICS FLOW IN DOCUMENTATION

Platform Subsystem Drawings & Mfg. and Supplier

Control Plans Work Instructions

Created This document is the property of Whirlpool Corporation. It contains confidential

8. OVERVIEW OF SUGGESTED IMPLEMENTATION

DFME A Description Criteria Required Action

MIC identified on the

Created This document is the property of Whirlpool Corporation. It contains confidential

MIC identified on the

Created This document is the property of Whirlpool Corporation. It contains confidential

9. GENERAL ACCEPTANCE CRITERIA

10. ACTION TO BE TAKEN

1. increase characteristic tolerance

2. to reduce process variation

3. 100% inspection, when it is not possible to do 1 or 2

11. CONTROL PLAN

12. INITIAL PROCESS STUDY

13. CONSIDERATIONS FOR RATIONAL SUBGROUPING AND SAMPLING

Created This document is the property of Whirlpool Corporation. It contains confidential

• Example of sampling plan on an injection molding process

• Crossed studies might produce systematic effects due to interactions.

14. SEVERITY RANKING FOR PRODUCTS

15. OCCURRENCE RANKING FOR PRODUCTS

16. POTENTIAL VS. CONFIRMED SPECIAL CHARACTERISTICS

All Special Characteristics are to be reviewed in a producibility review.

Critical characteristics require a safety review.

16.1 Confirmation of a Special Characteristic:

16.2 Correlation between Special Characteristics:

16.3 Options for removal of Design Critical Characteristics:

Created This document is the property of Whirlpool Corporation. It contains confidential

16.4 Options for removal of Process only Critical Characteristics:

16.5 Options for removal of Design High Impact Characteristics:

16.6 Options for removal of Process only High Impact Characteristics:

17. Producibility review for Special Characteristics

• A review of Potential vs. Confirmed Special Characteristics.

• Under no circumstances is “Life of Tool” to be granted for a boat ed dimension.

Created This document is the property of Whirlpool Corporation. It contains confidential

Created This document is the property of Whirlpool Corporation. It contains confidential

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Cpk 𝑅𝑅� ��