Control Plan
Introduction: What You Will Learn Areas to Improve Control &
Reaction Plans
Understand purpose and content for:
This material is presented to: Prototype Control Plans
Address Supplier and Customer needs by Pre-Launch Control Plans
improving the effectiveness of Control Plan and Production Control Plans
Reaction Plans. Product Characteristics & Features
Show linkages with other quality processes in Process Parameters & Variables
an overall quality plan. Specifications / Tolerances
Eliminate current errors in Control Plans & Evaluation / Measurement Technique
reactions to out of control conditions Sample Size and Frequency
Encourage your participation to work together Control Method
and deliver standardized processes with Reaction Plan
reduced variation and higher quality products.
Important Linkages - FMEA
Design and Process FMEA’s are the two most
important inputs to Control Plans
Important Control Plan Linkages
Control Plans are related to other crucial quality tools and
key cross functional processes including:
Important Linkages
FMEA’s are necessary and required!
They are a crucial link in the cascade of design & development planning
tools - and Ford quality objectives.
Design FMEA
–Identifies potential Product design failure modes before they are integrated into the
product design.
–Identifies potential Critical (YC) and Significant Characteristics (YS)
Process FMEA
–Identifies potential Process design failure modes before they are integrated into the
process design.
–Identifies potential Critical (CC) and Significant Characteristics (SC)
When Is a FMEA Complete?
DFMEA - Definition
Design or Concept FMEA is a:
–Systematic Approach
–Used by a design responsible team
–To assure potential design failure modes and their
associated causes have been considered and
addressed.
–Design FMEA’s are developed concurrently with
the product design allowing recommended actions
and the results of prototype testing to improve the
design.
DFMEA
Design FMEA has a core team - Led by Design & Release Engineer
and must include the appropriate Process Engineer
This assures cross functionality – include Subject Matter Experts as
required
PFMEA - Definition PFMEA Quick Reference
Process FMEA is a: Team Make-Up
–Systematic Approach –PFMEA core team must include an appropriate
–Used by a manufacturing responsible team Process Design Engineer
–To assure potential process related failure modes and –If DFMEA does not exist, the team must have a
their associated causes have been addressed and meeting with the Design Engineer - using the
resolved cross-functional approach
–Process flow diagrams and potential SC and CC’s from –Include Subject Matter Experts as required
the DFMEA are used to ensure –
•Process analyzed in process sequence
•All critical or likely failure modes are addressed
•Error proofing is incorporated
PFMEA - Quick Reference DFMEA & PFMEA – Quick Reference
Document Inputs Failure Modes: For each product or process function
–Process flow and all its measurables, use these four thought
–The DFMEA or Special characteristic list from DFMEA starters:
No Function
–Process characteristic matrix Partial / Over Function / Degraded Over Time
–Process requirements (production rates, location, etc.) Intermittent Function
–Regulatory requirement review Unintended Function
–PFMEA, quality history, & lessons learned from similar
processes
Attach these documents to your FMEA
Special Characteristics Classifications
Linkage to Other Documents
Special Controls
Special controls are:
–An interim control directed by manufacturing.
–Aimed at detecting and containing a special
characteristic-related defect prior to shipment.
–Special controls associated with Critical and Significant
Characteristics that are confirmed in the Process FMEA
must be documented and communicated via a control
plan.
APQP Process Steps
APQP Process Steps & Elements Relationship
FAO APQP Element Chart
What is a Control Plan ?
3 Different types of Control Plans
3 Different types of Control Plans
3 Different types of Control Plans
3 Different types of Control Plans
3 Different types of Control Plans
Where Control Plans Fit
Improving Control Plans
Common Mistakes
The DFMEA and/or PFMEA are not properly The control plan was not developed in the proper
reviewed for completeness in preventing sequence
problems. The Reaction Plan has not been evaluated for
There are no clear links to customer effectiveness, including containment based on probability
requirements. of detection.
There are missing key product or process Control Plan does not include outside activities,
characteristics. receiving, packing, shipping, and periodic control
The Control Plan is not utilized when developing requirements (annual layout).
standard work or operator instructions. There is a lack of sufficient process validation data
The Control Plan is not updated to current (capability, tolerances).
manufacturing practices on the floor.
Accuracy and precision of the Measurement
Systems are not verified after production data
have been made available.
Control Plan Form 1. Prototype, Pre-Launch, Production
2. Control Plan Number
3. Part Number Latest Change Level
4. Part Name Description
5. Supplier/Plant
6. Supplier Code
7. Key Contact/Phone
8. Core Team
9. Supplier/Plant Approval/Date
10. Date (orig.)
11. Date (Rev.)
12. Customer Engineering Approval/Date
13. Customer Quality Approval/ Date
14. Other Approval/Date
15. Part/Process Number
16. Process Name/Operation Description
17. Machine, Device, Jig, Tools for Manufacturing
18. Number
19. Product
20. Process
21. Special Characteristic Classification
22. Product/ Process Specification/ Tolerance
23. Evaluation/ Measurement Technique
24. Sample Size/ Frequency
25. Control Method
26. Reaction Plan
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Control Plan Form – Description of elements
Summary – Important Items to Remember
Team effort with PD and Supplier
Continuous improvement to the Control
Plan
Linkages with FMEA’s / APQP Process
Know the floor ……and walk the floor !
Know how to control the process … it
controls parts!
Drive understanding in Process & Part
Specifications, Tolerances, and
Measurement
Make the Reaction Plan section of the
Control Plan mistake proofed - omit or
overlook nothing !
Create a feedback loop of changes into
your QOS
Example Control Plan
