Welcome

To
Control Plan
Awareness Training Program

By
Manoj Maurya
Bhushan Management Services
COMPREHENSIVE BUSINESS SOLUTION

+91-9616498682 manoj.maurya15@gmail.com
Control Plan

• Control the risks identified in the P-FMEA (High RPNs)

• A structured approach to control process and product characteristics
• Focuses 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

Control Plan, Objective

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
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

• Verify if defined steps are followed

• Audit the process by Control Plan on a regular base.

• Update the Control Plan consistently

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
 Control Plan

CONTROL PLAN Control Plan No.

Prototype Pre-Launch Production Key Contact Person : Original Date:

Part Description: Plant Approval Sign: Rev. No. / Date:

Part No. / Drg. No.: Core Team : Customer :

Characteristics Methods
Process Description

M/c,

Corrective Action
Reaction Plan &
Primary Alternate
Process No.

Device,
Product / Measurement Measurement Sample Control Method
Jig, Class
Tools, No Process - Control Control
Product Process
Fixture . Specifications Preventio
/ Tolerance Detectio
for Mfg. MMR L.C. MMR L.C. Size Freq n (Error
n control
Proofing)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

A B C D
Operation Characteristic Methods Reaction Plan
Advanced Product Quality Manual (APQP) Reference Manual, QS-9000
Control Plan

What is being done? Process

M/c, Device,
Jig, Tools,
Process No.
A Operation Description Fixture for
Mfg.

1. Part/Process No. 1 2 3

Usually referenced from the process flow chart, PFMEA or Tool sheets

2. Process Name/Operational description

Identify the process/operation that best describes the activity being addressed
(e.g. work elements)

3. Machine, Device, Jig, Tools, Fixture for manufacturing

Identify the processing equipment required. (e.g.. machine, device, jig power
tools, assist arms, conveyors, etc.)
Control Plan

Characteristics

What is important? No. Product Process Class

B Characteristics 4 5 6 7

4. Number
Identifies the cross reference number from the applicable documentation.

5. Product Characteristics
Distinguishing features and/or attributes

6. Process Characteristics
Characteristics of the process

7. Special Characteristics (Class)

Key processes (Major, minor etc.)
 Control Plan

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

• Physical properties of part. • Identified characteristics which when

• Identified important customer controlled, reduce variation in product
characteristic (CTQs and Delta –K) characteristics.
Examples: Length, width, tensile
Examples: Pressure, Temperature, force,
strength, hardness, color, alignment etc.
RPM etc.

A description of the state of the

component or vehicle after Related to the product characteristics
the particular operation is completed
Control Plan

What is means for controlling?

Methods
Primary Alternate
Product / Process - Measurement Measurement Sample Control Method
Specifications / Control Control
Tolerance Detection Prevention
MMR MMR L.C. Size Freq

C Method
control (Error
8 9 10 11 12 13 14 15 16

8. Product/ Process specification

Specifications/tolerance for a part or process. (eg. may be obtained from various

engineering documents)

9-12- Evaluation/Measurement Control

Identifies the measurement system being used to measure product/process

characteristics. (eg. gages, fixtures, test equipment, blocks, go/no go, etc)

13-14 - Sample Size/Frequency

List sample size and frequency to perform evaluation. (eg. size: 4pieces /
frequency: fifth time per shift)
Control Plan

Sample Size & 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

 
 
Control Plan, Control Method

Methods
Primary Alternate
Product / Process - Measurement Measurement Sample Control Method

C Method Specifications /
Tolerance
Control
MMR MMR
Control
L.C. Size Freq
Detection Prevention
control (Error
8 9 10 11 12 13 14 15 16

15-16 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, material, etc) – Variation control charts
– Error/mistake proofing
- Preventative tooling – SPC charts
Control Plan, Reaction Plan

Reaction Plan

D Reaction Plan
& Corrective
Action

17
17. 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
 Control Plan, Examples

CONTROL PLAN Control Plan No.CP/G/ Moulding (Prod)

Prototype Pre-Launch Production Key Contac t Person : Dilip Parida Original Dat e: 01.04.2017

Part Desc ription: Moulding (Prod) Plant Approval Sign: Rev. No. / Date: 01 /15.10.2018

C o r r e c ti v e A c t i o n
R e - w o r k / r e c h e c k R&e a c ti o n P l a n &
Part No. / Drg. No.: Generic Core T eam : DP,SP,MS,SD,MKM,PP Cust omer : All
Process N o.

D e s c r i p ti o n

Charac terist ic s Methods

M/c ,
M o u l d i n g M a c h in e - A R P A 3 0 0 , / A R P A - 1 3 0 0 P a tt e r n N o . - - ,
Process

Devic e, Primary Alt ernate

C la s s
Produc t / Measurement Measurement Sample Cont rol Met hod
Jig,
No Proc ess - Control Control
T ools, Produc t Proc ess
. Spec ific ations

e f o r e t a k i n g p r o d u c ti o n
Fixt ure Prevention

m o u l d i n g b o x c o n d i t io n
/ Toleranc e Detec t ion
for Mfg. MMR L.C. MMR L.C. Size Freq (Error

I n s p e c t io n a s p e r s a m p le s iz e &E n s u r e th e p a tt e r n &
c ont rol Proofing)
Daily
before
Free from
1 Patt ern Visual --- --- Onc e taking to
damages et c . productio

correct
n
Patt ern Patt ern should Each
2 Visual --- --- 100%
M o u ld in g B o x , A ir G u n ,

mount ing be c lamped setup

Fre e from sand

m o u ld in g p r o c e s s c o n t r o l& m o n it o r in g
box
Moulding Each
3 breakage ,prop Visual --- --- 100%
M o u l d M a k in g

P R O D /W I/05
box setup

fre q u e n c y d e fin e d & r e c a r d e d in

e r se ating on

b
matchplate
Pressure 1Kg/c m
4 Air pressure 6- 8.5 Kg/c m2 --- ---
Gauge 2
60
Each

re p o r t - P R D /F /0 4

C he ck & R e -se t
5 Jolting time 5- 8 Sec . Cloc k 1 Sec --- --- Onc e setup
Sqeezing
6 3- 4 Sec . Cloc k 1 Sec --- ---
time
Mould No breakage
7 Visual --- --- 100% C ont…
c ondit ion /damages
Hardness Hardness
8 70-85 1 --- --- 5%
Vert ic al t est er
Hardness Hardness
9 80-95 1 --- --- 5% Per
Horizontal t est er Batch
Mould 2
10 c oat ing(Opti 13-14 Sec B4 Cup 1 --- --- Onc e
onal) per
01/15.10.2018 Air pressure range inc reased from- 6.0- 6.5 to 6.0- 8.5)
00/ 01.04.2017 New Release
Rev. No. / Dat e Change Det ails summary

Prepared By Approved By
Control Plan, Next steps

1. Know your customers’ expectations CTQ’s (Critical to Quality Characteristics)

2. Have a defined and documented production process
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.
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.
List of acronyms:

• 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

• PPAP: Product Part Approval Process

• APQP: Advanced Project Quality Plan

Our Services

Bhushan Management Services

+91- 9616498682

Manoj.maurya15@gmail.com