OVERVIEW

M
A An aid to manufacture of Quality products to
R meet Customer Satisfaction
S Control Plan does not replace the Operator
Instruction / Work Instruction etc
C Integral part of Overall Quality system and is a
O “LIVING DOCUMENT”
N
S Single Control plan may apply to a group or family
U of products
L Maintained and used throughout the product life
T cycle
A
N Reflects the current method of control and
T measurement system used
S
CONTROL PLAN
 EFFECTIVE CONTROL PLAN
M
A Basic understanding of the process
R
S Cross Functional Team approach is required

C Information's from the following shall be obtained

O
n Process Flow Diagram
N
S n Process Failure Mode & Effect Analysis
U
L n Special Characteristics
T
n Lessons learnt from previous parts
A
N n Team’s knowledge on the part
T
S n Optimization Methods
CONTROL PLAN
 BENEFITS OF CONTROL PLAN
M
A QUALITY
R
S n Reduces Waste & Improve the quality

n Thorough Evaluation of the product / process

C
O n Identifies the input parameters and their variables
N
S Customer Satisfaction
U
n Control Plan focus resources on processes & products
L related to parameter
T
A nCommunicates changes in the product / process, control
N method and characteristics measurement
T
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M 1
Prototype Pre-launch Production
CONTROL PLAN
Key Contact/Phone Date (Org) Date (Rev)

A Control Plan Number:

2 7 10 11
Part Number/Latest Change Level:
3 Core Team
8 Customer Engg Approval /Date(If
12
reqd.)

R Part Name / Description:

4 Supplier/Plant Approval Date
9 Customer Quality Approval/Date
13reqd.)
(if

S Supplier Plant:
5 Supplier Code
6 Other Approval/Date (If Reqd.)
14 Other Approval / date
14

Characteristics
Characteristics Methods
Part / Process Name / Machine,

Special
Process Operation Device, Jig,
Product / Process Evaluation
Number Description Tools for Mfg. Sample Control
No. Product Process Specification / Measurement Frequency Reaction Plan
Size Method
Tolerance Technique

C 15 16 17 18 19 20 21 22 23 24 24 25 26
O
N
S
U
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T
A
N
T
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M
Id
A no.
Title Description
R Prototype: Occurring during Prototype built
S Prototype / Pre-launch: After Prototype and before normal production
1 Pre-launch / Production: Comprehensive documentation of product,
Production process characteristics, process controls, tests &
measurement system occurring during normal production
C
Control Plan
O 2 Document Number for tracking
No.
N Part
No. of systems/subsystems/components with latest change
3 No./Latest
S Change Level
level
U Part Name Enter the name and description of the product being
4
L Description controlled
T 5 Supplier/Plant
Name of the company & division/plant/dept. preparing the
control plan
A
6 Supplier Code An identification no. as requested by customer
N
T 7
Key Contact
Name and tele no. of the primary contact person
/Phone
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M
Id
A no.
Title Description
R Name and tele no. of individuals responsible for preparing
8 Core Team
S control plan
Supplier/Plant
9 Responsible manufacturing plant approval
Approval/Date
C 10 Date (Org) Original date of control plan preparation
O
11 Date(Rev) Latest control plan update date
N
S Customer
12 Engg. Engineering Approval
U Approval/Date
L Customer
Responsible supplier quality representatives approval (if
13 quality
T approval/Date required)
A Other
14 Any other agreed approval (if required)
N approval/Date
T Part/Process o Referred from the process flow chart
15
Number o If multiple part no. exists, list the individual part nos.
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M
Id
A no.
Title Description
R Process
All steps in the manufacturing of a component as described in
S 16 Name/Operati
the PFD
on Description
Machine,
C 17 Device, Jig, For each operation identify all required
Tool for Mfg.
O Cross reference number from all ref. Doc. Like PFD, PFMEA
18 Number
N etc.
S • Features of part, component or assembly that are described
Product on drawing
U 19
Characteristic • The team shall identify any special characteristics
L • All special characteristics shall be specially marked
T Process Process variable (Input variable) that have a cause and effect
20
A Characteristic relationship with the identified product characteristic

N • Use customer designated symbol or choice of your own

Special
21 • Parameter that affect customer safety, compliance with
T Characteristic
regulation, function, fit or appearance
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M
Id
A no.
Title Description
R Product/
S 22
Process Specification/Tolerance that are obtained from engg. Std,
Specification/ material std, mfg and/or assembly requirements
Tolerance

C Evaluation/ • Identify the measurement system being used

23 Measurement
O technique • May include gauge, fixture, tool and/or test equipment
N 24
Sample Size/ When sampling is required, list corresponding sample size and
Frequency frequency
S
• Brief description of how the operation will be controlled
U including procedure no.
L 25
Control • Control method may include SPC, Inspection, attribute
Method data, mistake proofing and sampling plan
T
• Method of control should be continually evaluated for
A effectiveness of process control
N
T
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M
Id
A no.
Title Description
R Specify the corrective action necessary to avoid producing NC
S products
Action should normally be the responsibility of the people
26 Reaction Plan closest to the process
C Suspect and NC product must be clearly identified and
disposed by the responsible person designated in the reaction
O plan
N
S
U
L
T
A
N
T
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
M CONTROL PLAN

A Prototype Pre-launch Production Key Contact Person / Phone Date (Original) Date ( Revised)

R Control Plan Number

Part Number / Latest Change Level Core Team Customer Engg Approval Date (If)

S Part / Name Description Supplier/Plant/Approval Date Customer Quality Approval Date (if)

Supplier Plant Supplier Code Other Approval / Date (if) Other Approval / Date (if)

C
O << Back1
N
S
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A
N
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CONTROL PLAN
 Part /
STAGES OF CONTROL PLAN
Process /
Machine,
Spl
M Process Operation
Device, Jigs,
Char Product / Process
Fixtures, Tools,
A # Description
etc for Mfg.
No Product Process Class Specification /
Tolerance
R 40 Drilling M/c: DR002
Jig: J030
S Drill: 16mm

C
O
N
S
U
L
T Specify the
A Operation/ Describe the
Process No Specify the types of
N kind of machineries /
T operation equipment / tools to be
that needs to used with their id codes
S be controlled
CONTROL PLAN
 STAGES OF CONTROL PLAN
M Machine, Characteristics
A Part / Process /
Device, Jigs,
Spl
Process Operation Char
R Fixtures, Tools, No Product Process
# Description Class
S etc for Mfg.

40 Drilling M/c: DR002 PFD/05/01 Speed

Jig: J030 PFMEA/05/40 Feed
C Drill: 16mm Depth of cut
O Dia
N
S
PCD M
U
L
T
A
N Identify any
Refer to all Specify the Specify the
T relevant / characteristics characteristics characteristics
that require
S applicable
documents
related to
PRODUCT
related to
PROCESS additional care

CONTROL PLAN
 STAGES OF CONTROL PLAN
Spl
M Char Product / Process Evaluation Sample Reaction Plan
Control
A Process Class Specification / /Measurement
Size Frequency Method
Tolerance Techniques
R Speed 1400rpm Visual During Setting
S Feed 0.2mm/min Visual Continuous
Depth of cut 0.2mm Visual Continuous
16.1+/-0.2 VC (LC:.02) 5 Nos First off FLIR
5 Nos Last off FLIR
C 5 Nos Every hr IIP
O M 172.5+/-0.1 VC (LC:.02) 5 Nos First off FLIR
5 Nos Last off FLIR
N SPC
10 Nos Every hr
S Chart
5 Nos Every hr IIP
U
L
T
Specify Specify the Define the Define the methods that are
A product/process techniques used sample sizes used for monitoring,
characteristics in
N a complete
to evaluate the from the lot to recording and controlling the
product/process be inspected at information
T manner conformity determined
frequency
S
CONTROL PLAN
 STAGES OF CONTROL PLAN
Machine,

M Part /
Process
Process /
Operation
Device, Jigs,
Fixtures, Tools,
Spl
Char Product / Process Evaluation Sample Control Reaction Plan
No Product Process Specification / /Measurement
A # Description
etc for Mfg.
Class
Tolerance Techniques Size Frequency Method

40 Drilling M/c: DR002 PFD/05/01 Speed 1400rpm Visual During Setting Inform Supervisor
R Jig: J030 PFMEA/05/40 Feed 0.2mm/min Visual Continuous Strengthen PM
Drill: 16mm Depth of cut 0.2mm Visual Continuous
S Dia 16.1+/-0.2 VC (LC:.02) 5 Nos First off FLIR Change Setting
5 Nos Last off FLIR Inform Setter
5 Nos Every hr IIP Change Setting
PCD M 172.5+/-0.1 VC (LC:.02) 5 Nos First off FLIR Change Setting
5 Nos Last off FLIR Inform Setter
C SPC Adjust the process,
10 Nos Every hr
O Chart Inform Supervisor

5 Nos Every hr IIP Change Setting

N
S
U
L
T Indicate the actions that
needs to be initiated when
A there is a deviation against
N the controls defined

T
S
CONTROL PLAN