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Control Plan Template

This document is a Lean Six Sigma control plan for a paint production process. It outlines the key process variables and characteristics that will be monitored, including gun angle, gun distance, air pressure, paint transfer efficiency, and fixture flatness. For each characteristic, it specifies the measurement method, target value and tolerance ranges, sampling frequency, who is responsible for measurement and recording, and the corrective actions to be taken if values are out of specification. The overall goal is to control the critical process parameters and maintain process capability.

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Puneet Sharma
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114 views3 pages

Control Plan Template

This document is a Lean Six Sigma control plan for a paint production process. It outlines the key process variables and characteristics that will be monitored, including gun angle, gun distance, air pressure, paint transfer efficiency, and fixture flatness. For each characteristic, it specifies the measurement method, target value and tolerance ranges, sampling frequency, who is responsible for measurement and recording, and the corrective actions to be taken if values are out of specification. The overall goal is to control the critical process parameters and maintain process capability.

Uploaded by

Puneet Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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Prepared by:

Approved by:
Location: Approved by:
Area: Approved by:
KPOV KPIV
Measurement
Method
Process Process Step
Specification
Characteristic
Specification/
Requirement
USL LSL
CTQ
Sample Size
Lean Six Sigma Control Plan
Customer
Process Name:
Int/Ext
Page: of
Document No:
Revision Date:
Supercedes:
Who
Measures
Sample Size Frequency
Where
Recorded
SOP Reference
Decision Rule/
Corrective Action
Lean Six Sigma Control Plan
Prepared by: Page: of 1
Approved by: Document No:
Location: Approved by: Revision Date:
Area: Approved by: Supercedes:
KPOV KPIV
X
X
X
X
X
X
X
Protractor 1
Gun Setup
Sheet
Quarrentine work for
QA Inspection
Work Instruction
#001
Direct read from
ruled arm.
1 Per shift
Paint
Technician
Top and
Bottom Gun (if
used)
Gun Angle
Target value
specified on Gun
Setup Sheet.
Range = +/- 5
degrees from
Target.
Gun Setup All Gun Distance
Target value
specified on Gun
Setup Sheet.
Range = +/- 20mm
from Target.
Measurement
Method
Who
Measures
Sub Process
Sub Process
Step
Specification
Characteristic
Specification/
Requirement
USL LSL
CTQ Sample
Size
Frequency
Paint
Engineer
TE Control
Chart
Stop process and
Investigate for root
cause. Continue only
when back in Control
Per shift
Paint
Technician
Quarrentine work for
QA Inspection
Static Air
Pressure Gauge
Work Instruction
#003
Gun Setup
Sheet
Gun Setup
Sheet
Quarrentine work for
QA Inspection
Work Instruction
#001
Quarrentine work for
QA Inspection
Work Instruction
#001
Paint
Paint
Application:
Topcoat and
Basecoat
Paint Transfer
Efficiency
PPG Materials:
Average TE > 35%
basecoat or topcoat
Part wieght gain
(see SOP)
5 Data
Points per
sample
Once per
week
Protractor 1 Gun Setup
Top and
Bottom Gun (if
used)
Arm Angle
Target value
specified on Gun
Setup Sheet.
Range = +/- 5
degrees from
Target.
Paint
Technician
Gun Setup
Sheet
Per shift
Per shift
Paint
Technician
Gun Setup
Work Instruction
#001
Process
Monitoring
Sheet
Quarrentine work for
QA Inspection
Work Instruction
#001
Gun Setup All
Gun Height
(impact point)
Target value
specified on Gun
Setup Sheet.
Range = +/-20mm
from Target.
Direct read from
ruled arm.
1
1 Hourly
Paint
Technician
Gun Setup
Pressure
setting
Atomization
Pressure
Target value
specified on Gun
Setup Sheet.
Range specified on
Process Monitoring
Sheet.
Where
Recorded
SOP Reference
Decision Rule/
Corrective Action
Lean Sigma Process Control Plan
Customer
Process Name:
Int/Ext
Paint Production Process
XXX
Paint Shop
YYY
1
Preventive
Maintenance
Part Fixtures Fixture TIR
All fixtures must be
welded
Visual
Inspection
100%
Twice per
week
Shift
Supervisor
Bi-Weekly
PM Log
All bent, damaged
and unwelded fixtures
must be replaced with
welded undamaged
fixtures
Fixture Print

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