Part A

Process Control Plan

The Control Plan is a document that describes the actions (measurements, inspections, quality
checks or monitoring of process parameters) required at each phase of a process to assure the
process outputs will conform to pre-determined requirements. A Control Plan is often a
Production Part Approval Process (PPAP) requirement for suppliers of parts.[ CITATION Qua \l
1033 ]
In simpler terms, the Control Plan provides the operator or inspector with the information
required to properly control the process and produce quality parts or assemblies. It should also
include instructions regarding actions taken if a non-conformance is detected. The Control Plan
does not replace detailed operator instructions. In some cases the Control Plan is used in
conjunction with an inspection sheet or checklist. The Control Plan helps assure quality is
maintained in a process in the event of employee turnover by establishing a standard for quality
inspection and process monitoring. Control Plans are living documents that should be
periodically updated as the measurement methods and controls are improved throughout the life
cycle of the product.
A Control Plan contains following key information:[ CITATION Hys \l 1033 ]
 Identification of the control factors
 The specifications and tolerances
 The measurement system
 Sample size and frequency
 The control method
 The reaction plan
A simple control plan is described in the below figure:
 Figure 1: Process control Plan

The Three Levels of Control Plans

Prior to completing the Control Plan development, the team must determine the proper level
appropriate for the process being controlled. There are three designations for a Control Plan level
based upon what point the product is at in the New Product Introduction (NPI) process. They are
as follows:[ CITATION Qua \l 1033 ]
 Prototype – This level Control Plan should include descriptions of the dimensions to be
measured and the material and performance tests to be completed during the prototype
build
 Pre-Launch – This level of Control Plan should contain descriptions of the dimensions to
be measured and the material and performance tests to be completed after prototype but
prior to product launch and regular production
 Production – This level of Control Plan should contain a comprehensive listing of the
product and process special characteristics, the process controls, measurement methods
and tests that will be performed during regular production
A control plan includes the following things:[ CITATION Gre \l 1033 ]
 Control number:
Provide a reference number. This number may be supplied by the responsible department.
 Team members:
If a cross functional team is involved, provide the members names.
 Contact person:
This could be the black belt in charge of the project, however, the name and function of
the process owner are more important.
 Page:
 Provide page numbers if the control plan exceeds one page. Control plans may run up to
20 pages.
 Original date:
Indicate the original date of issue of the control plan.
 Revision date:
Provide the latest revision date of the control plan.
 Part/process:
List the part number or the process flow being charted.
 Key input variable (X):
Note the key input variable, when appropriate.
 Key output variable (Y):
Note the key output variable, when appropriate.
 Special characteristic/Class note:
Indicate if a special characteristic is to be monitored and controlled.
 Specifications:
For manufacturing applications, the engineering specifications for the part should be
monitored and controlled.
 Measurement gage technique:
The gage or measurement technique should be described. The gage, tool, fixture, or test
device used for data collection must be in conformance with the needed measurement
system analysis (MSA) requirements.
 Gage capability:
Provide the current capability of the measurement system.
 Sample Size:
Provide the Sample frequency, List how often the inspection or monitoring of the part or
process is required.
 Initial CPR:
This provides an indication of process capability.
 Person responsible for measurement:
Indicate who will make and record the measurement.
 Control method:
Note how this X or Y variable will be controlled. Examples include
 Checklists
 Visual inspections
 Automated measurements
 Reaction plan:
Control plan construction is often led by the black belt in charge of the six sigma project.
The team is usually cross functional with individuals from different areas, including the
process owner. The team will ensure that the control plan contains the critical variables,
the Xs and the Ys, of the product or process. The control plan must show compliance and
control before project closure. A successful control plan should remain a living document
to ensure that the benefits of the project are fully realized
A control plan is shown in the below table:

Control Plan
Control Plan Number Key Contact Date Original Date Revised

Part Number Core Team Customer Engineering Approval Date

Part Name Supplier/Plant Customer Quality Approval Date

Approval/Date
Organization Other Other Approval Date
Approval Date
Part/P Process Machine. Characteristi Spec. Methods React
rocess Name/Oper Device.Ji cs Chara ion
Numb ation g.Tool cter/Cl Plan
er Description N Pr Pro ass Specifi Eval Sam Co
o od cess cation uati ple ntr
. uc Tolera on ol
t nce Tec S F M
hniq i r et
ue z e ho
e q d
.
1 Dimension Inner 1 M Me D ±10% Rec 2 P Sa Infor
Inspection Diameter ac asur ord 0 e m m
Gauges hi e r pli Super
ne B ng visor
sle at
ev c
es h
Di
a
m
ete
r

Process Capability Analysis

Process capability is defined as a statistical measure of the inherent process variability of a given
characteristic. A process-capability study can be used to assess the ability of a process to meet
specifications.[ CITATION ASQ \l 1033 ]
An important technique used to determine how well a process meets a set of specification limits
is called a process capability analysis. A capability analysis is based on a sample of data taken
from a process and usually produces:[ CITATION Sta \l 1033 ]
i. An estimate of the DPMO (defects per million opportunities)
 ii. One or more capability indices
iii. An estimate of the Sigma Quality Level at which the process operates
LSL USL
45 90
Batch B1 B2 B3 B4 B5
no
1 53 73 55 52 80
2 57 68 59 77 64
3 72 73 50 87 53
4 76 77 57 88 57
5 66 77 78 79 69
6 87 72 81 71 81
7 86 76 84 78 70
8 77 58 72 65 54
9 75 49 52 58 54
10 65 74 52 76 62
11 54 71 79 86 74
12 59 53 64 58 50
13 73 80 63 63 56
14 74 74 75 56 60
15 63 86 56 68 51
16 71 51 82 71 51
17 73 77 69 59 72
18 88 54 54 56 84
19 77 58 72 65 54
20 72 73 50 87 53
mean 70.9 68.7 65.2 70 62.45
s 10.20784 10.78059 11.87479 11.73838 11.07617

Control Limit Calculations

For x-Bar
∑ xbar
x−double ¯¿
k
x−double ¯¿ 67.45
UCL=x −double + ¯A 3∗s−¯¿

UCL=67.45+ 0.68∗11.1355=75.022
UCL=x −double −¯A 3∗s−¯¿

UCL=67.45−0.68∗11.1355=59.88
 ( x −double −LCL
¯ )∗ √ n
σ=
3
σ =11.29
Now for S-Bar
∑s
s− ¯¿ =11.1355
k
UC Ls=B4∗s−¯¿ 1.49∗11.1355=16.59

UC Ls=B3∗s−¯¿ 0.51∗11.1355=5.68

( s−−LCL
¯ )
σ s=
3
σ s=1.82

USL−LSL
CP=
6 σs

45
CP= =4.12
6∗1.82
¯
C PK =USL−Double x ¿ ¿
3σs

90−67.45
C PK = =4.09
3∗1.82

Trends Observed in Control Charts

Trends observed in x-bar is:
Trends observed in s chart is:

There are no points outside the limits which indicated that the production is going well.

Defective Chart Table

Time Nk ck 16 180 12
1 150 10 17 190 1
2 170 11 18 170 11
3 130 9 19 170 5
4 152 12 20 170 5
5 150 10 21 160 12
6 130 11 22 170 3
7 170 9 23 170 5
8 170 11 24 140 9
9 170 12 25 130 0
10 150 9 26 150 7
11 160 7 27 140 5
12 160 10 28 170 7
13 160 3 29 168 8
14 150 10 30 140 4
15 130 7 31 150 11
Trends of np-chart of defective:

This chart also indicates that the production is going well.

References

[1] "Quality-One International," [Online]. Available: http://quality-one.com/control-plan/.

[2] "Hyster-Yale Group," [Online]. Available: http://s21.q4cdn.xn--com%20%%20newpptweb
%20resultscontrol%20plan%20training-jb271.
[3] "GreyCampus," [Online]. Available: http://www.greycampus.com/opencampus/lean-six-
sigma-green-belt/elements-of-control-plan.
[4] "ASQ," [Online]. Available: http://asq.org/quality-resources/process-capability.
[5] "Statgraphics 18," [Online]. Available: http://www.statgraphics.com/process-capability-
analysis.