Control Plan Training

Control Plans

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 Control Plan

Control Plans:
• Control the risks identified in the P-FMEA (High RPNs)
• A structured approach to control process and product characteristics
• Focusses on Customer Requirements
• Assure reaction plans are in place in case of out-of-control conditions
• Provide a central document for communication of control methods
• A Control Plan contains following key information:
 Identification of the control factors
 The specifications and tolerances
 The measurement system
 Sample size and frequency
 The control method
 The reaction plan
• Control Plans are living documents, just like FMEA’s

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 Control Plan, Objectives

Objectives of the training:

• To understand the use of a Control Plan
• To learn the steps to develop a Control Plan
• To learn how to link each step in the Control Plan
to the FMEA

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 Control Plan, Summary

Control Plan, a systemic way to Control a process:

• Define Characteristics per process step:
• Machines, Devices, Jigs and Tools
• Product, Process and Special characteristics
• Define Methods per process step:
• Process and Product Specifications and Tolerances
• Measurement and Inspection techniques
• Sample size and frequency
• Actions that should be taken in case of
Non Conformities

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 Control Plan, Summary

Control Plan, a systemic way to Control a process:

• Verify if defined steps are followed

• Audit the process by Control Plan on a regular
base
• Update the Control Plan consistently

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Benefits Control Plan, Inputs

Control Plan, inputs might include following tools:

• FMEA
• Flow Chart (process sequence)
• Lay-out Plan production line
• Sequence Of Events
• Part Number/ Tooling / Tool List
• Assembly Drawing
• Specifications/ Dimensions/ Tolerances
• CTQ List
• Process Map
• Historical OMS
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 Control Plans, Planning
A build B build Pilot SOP

Drawing

Issue part approval form

Tool development

FMEA + control plan

Fit / performance

1. Conditional approval
Purchasing SQE QA 2. HVPT approval
3. Part approval

Source SQE approval

Quality and capacity confirmation

Issue HF PA HVPT process approval
requirements

HF proto part MF and LF

approval part receipt

HF full part Inspection OK

approval – NOK send
(OT/OP) CAR’s

VCB approval
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 Control Plans

Prototype Pre-launch Production

Control Plan Number Key Contact/Phone Date (Original)
Part Number/Latest Change Level Core Team Date (Revised)
Part Number / Description Plant / Supplier Approval Date Customer Eng.'s Approval / Date (if Required)

Plant / Supplier Supplier Code Other Approval / Date (if Required) Customer Quality Approval / Date (if Required)

Part / Machine Device

Characteristics Special
Methods
Process Name / Reaction
Process Jig. Tools Characteristics Product/Process Evaluation Sample
Operation Description Plan
Number for Manufacturing No. Product Process Class Specification Measurement Control
tolerance Technique Size Freq. Method

1 2 3 4 5 6 7 8 9 10 11 12

A B C D
Operation Characteristics Methods Reaction
Plan

Advanced Product Quality Planning (APQP) Reference Manual, QS-9000

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 Control Plans
MACHINE,

What is being done?

PART/ PROCESS NAME/
DEVICE
PROCESS OPERATION
JIG, TOOLS
NUMBER DESCRIPTION
FOR MFG.
LTVL010 8416010, FRAME, 1x 1
A Operation
1. Part/Process Number:
• Usually referenced from the process flow chart, PFMEA or
Tool sheets
2. Process Name/Operation Description:
• Identify the process/operation that best describes the
activity being addressed (e.g. work elements)
• Use verb / noun format
3. Machine, Device, Jig, Tools for Manufacturing:
• Identify the processing equipment required. (e.g..
machine, device, jig power tools, assist arms, conveyors,
etc.)

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 Control Plans
MACHINE,

What is Important?
CHARACTERISTICS SPECIAL
DEVICE
CHAR.
JIG, TOOLS NO. PRODUCT PROCESS CLASS
FOR MFG.
1 1 Appearance Inspect the frame Y

B Characteristics
4. Number:
• Identifies the cross reference number from the applicable
documentation.
5. Product Characteristic:
• Distinguishing features and/or attributes
6. Process Characteristic:
• Characteristics of the process
7. Special Characteristic:
• key processes (e.g. Delta K, QS)

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 Control Plans
Characteristics: Identify Product and Process
characteristics for each Control Plan step

PRODUCT PROCESS
CHARACTERISTIC CHARACTERISTIC
• physical properties of the part • identify characteristics, which
• Identified important customer when controlled, reduce
characteristics (CTQs and variation in product
Delta-K) characteristics
Examples: length, width, tensile
strength, torque, weld integrity, color, Examples: pressure,
alignment, etc. temperature, force, feed rate,
RPM (torque), etc.
A description of the state of the
component or vehicle after the Related to product characteristics
particular operation is completed

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 Control Plans
C Methods What is the Means for Controlling?
8. Product/Process Specification:
• Specifications/tolerance for a part or process. (eg. may be
obtained from various engineering documents)
9. Evaluation/Measurement Technique:
• Identifies the measurement system being used to measure
product/process characteristics. (eg. gages, fixtures, test
equipment, blocks, go/no go, etc)
10 / 11. Sample Size/Frequency:
• List sample size and frequency to perform evaluation. (eg. size: 4
pieces / frequency: fifth time per shift)
METHODS
REACTION
PRODUCT/PROCESS EVALUATION/ SAMPLE
CONTROL PLAN
SPECIFICATION/ MEASUREMENT
SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works OMS Inform Trainer
hop

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 Control Plan,
Benefits
Sample size and frequency
• Until a process is Capable (Cpk 1.33), 100% Inspection is required
• If process is Capable, define Sample Size and Frequency reflecting acceptable risk
• Use Six Sigma tools and techniques to control the Process
Xbar-R Chart of x

10-nov-08
1-nov-08

2-nov-08

3-nov-08

4-nov-08

7-nov-08

8-nov-08

9-nov-08
5-nov-08

6-nov-08
UCL=51.01
50

45
Station:

Sample Mean
__
40
Install O-ring Mee-1247 1 X=39.42

35
C/R into C/C Mee-1248
30
S/R assy Mee-1250 LCL=27.82

S/R height Mee-1251 1 2 3 4 5 6

V-coupling assy Mee-1253 Counting Defects SPC Chart

Sample

Act assy Mee-1255 1 20 UCL=20.15

Lever welding Mee-1288 1 2 3 1 15

Sample Range
Lever welding Mee-1289
10
Act measurement Mee-1291 2 2 1 3 _
R=6.17
5
Engraving Mee-1256 1
Rev & K-ring check Mee-1257 0 LCL=0
1 2 3 4 5 6
Weld-assy-act Mee-1258 Sample

C/C angle check Mee-1259 1 4

Process Capability Report for x
V-coupl-lever-act Mee-1260 2 Torque Capability
Total NOK 3 2 1247 0 0 7 1 2 0 4
LSL USL
Process Data Overall Capability
LSL 46 Pp 0.05
OK 220 450 300 350 455 275 400 430 Target * PPL -1.73
USL 50 PPU 0.14
Sample Mean 39.7 Ppk -1.73
Sample N 10
Location 1.51014 Exp. Overall Performance
Scale 0.446987 PPM < LSL 897760.32
Threshold 34.0437 PPM > USL 56346.95
PPM Total 954107.27
Observed Performance
PPM < LSL 900000.00

C-Graph of Defects
PPM > USL 0.00

Capability Graph
PPM Total 900000.00

35 40 45 50 55 60 65 70

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 Control Plans, Control Method

C Methods
12. Control Method:
• Brief description of how the operation will be controlled
• When selecting the method of control, focus on:
• process control rather than product control
• prevention rather than detection
• targeting nominal rather than specification limits
Examples:
- Check sheets (weld, quality, tool, - Variation control charts
material, etc) - Error/mistake proofing
- Preventative tooling maintenance - SPC charts
METHODS
REACTION
PRODUCT/PROCESS EVALUATION/ SAMPLE
CONTROL PLAN
SPECIFICATION/ MEASUREMENT
SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works OMS Inform Trainer
hop

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 Control Plans, Reaction Plan

D Reaction Plan
13. Reaction Plan:
• Specifies who to inform to make a decision or what to do when a
process goes out of control
• Written for people closest to the process (e.g. replace a drill)
• Review systemic root cause and update the FMEA
Examples:
- Call supervisor
- 100% Inspection until the process is back in control
- Calibrate equipment
METHODS
REACTION
PRODUCT/PROCESS EVALUATION/ SAMPLE
CONTROL PLAN
SPECIFICATION/ MEASUREMENT
SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works OMS Inform Trainer
hop

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 Control Plans, Plug Example
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.) 1
1 Wytse Zijlstra 05/10/2016
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
PL30 Wytse Zijlstra, Stephen McLaughlin N/A
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
Plug assembly 15/10/2016 N/A
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Hyster-Yale Group H-Y N/A
MACHINE, CHARACTERISTICS METHODS
PART/ PROCESS NAME/ SPECIAL
DEVICE REACTION
PROCESS OPERATION CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE
JIG, TOOLS CONTROL PLAN
NUMBER DESCRIPTION NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT
FOR MFG. SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
PL-10 1010; 1 Plug face Code: PA320, Select 1 plug face w ith Visual Inspection 100% OMS Inform Trainer
White Bar Grip inside facing operator
Rew ireable 13A
Resilient Plug Top
PL-10 1345; 1 Cable Grip. 1 Assembly Fit 1x Cable Grip using 2 Y Ensure Cable Grip Hand tight 100% OMS Adjust/ re-check
1060; 2 cable screw s cable screw s. Screw hand screw s go through
tight back of cable grip
PL-10 Deliver batch of plugs to station 2 Box OMS Inform Trainer
PL-20 6789; 1 Fuse holder 2 Assembly Fit fuse holder Y Check correct location Visual Inspection 100% OMS Adjust/ re-check
of the fuse holder
PL-20 1011; 1 Live pin 3 Assembly Fit 1 Live pin Y Pin has fuse clamp on Visual Inspection 100% OMS Adjust/ re-check
top
PL-20 1213; 1 Neutral pin w ith black band on 4 Assembly Fit 1 Neutral pin Y Check if black band on Visual Inspection 100% OMS Adjust/ re-check
pin pin
PL-20 1415; 1 Earth pin Assembly Fit 1 Earth pin Check if pins are in Visual Inspection 100% OMS Adjust/ re-check
correct position
PL-20 1617; 1 fuse 13 Amp 5 Assembly Fit 1 fuse Y 13 Amp fuse Visual Inspection 100% OMS Adjust/ re-check
1616; 1 fuse 5 Amp 5 Amp for Euro

PL-20 Deliver batch of plugs to station 3 Box Deliver batch of plugs to OMS Inform Trainer
station 3
PL-30 2022; 3 screw s to connect w ires Screw driver 6 Assembly Fit 1 screw to Neutral pin, Y Ensure all screw s are Hand tight 100% OMS Adjust/ re-check
Earth pin and Live pin and nipped tight and unable
tighten hand tight w ith to undo by hand
screw driver
PL-30 Deliver batch of of plugs to station 4 OMS Inform Trainer
PL-40 1819; Plug Front 7 Assembly Fit Plug Front Y Ensure all screw s are Hand tight 100% OMS Adjust/ re-check
tight
PL-40 2013; Wiring diagram 8 Assembly Fit w iring diagram Y Ensure text is readable Visual Inspection 100% OMS Adjust/ re-check
PL-40 Deliver batch of plugs to QA Box OMS Inform Trainer

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 Control Plans, Next Steps
Next Steps to H-Y Suppliers:
1. Know your customers’ expectations - CTQ’s (Critical to Quality
Characteristics)
2. Have a defined and documented production process (SOE)
3. Follow 5S Principles
4. Employ a formal training system
5. Involve the people on the shop floor
6. Audit the production process constantly
7. Manage supplied parts and control supplier performance
8. Measure/monitor key quality performance indicators
9. Use an effective Corrective & Preventative Action Process

FMEA and Control Plans are mandatory for PPAP

submission level 3.

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Control Plans, Next Steps

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 Quality Focus Day Workshop

List of acronyms:
CTQ: Critical To Quality, a characteristic judged to be important to the fit and function of a component or assembly as well
as customer satisfaction
FMEA: Failure Mode and Effect Analysis
ICAM: Interactive Corrective Action Management
OMS: Operational Method Sheet
Off Tool: (Production Tooling) - When a part is said to be “Off Tool” it is required that the part be manufactured using the
exact tooling which will be used for long-term production. This does NOT mean the parts were manufactured from tooling
that is “like” or “similar” to the intended production tooling.
Off Process:(Production Process) – When a part is said to be “Off Process” it is required that the part be manufactured and
tested using the exact process that will be used for long-term production. This does NOT mean the parts were
manufactured using a “like” or “similar” or less than 100% completed process.
P.A.: Part Approval process to determine if part characteristics and specifications are understood and met by the supplier.
PCR: Process Change Request
PFD: Process Flow Diagram
SQM: Supplier Quality Manual
QFD: Quality Function Deployment
QS-9000, PPAP: Product Part Approval Process
QS-9000, APQP: Advanced Project Quality Plan

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