Control Plan Template

Introduction

In the modern competitive business environment, there is a need to ensure high quality of products and services provided by the company. Every organization strives to deliver defect-free goods and services to satisfy the customers and reduce costs associated with rework and rejections. The control plan is a document, which contains specific procedures for controlling processes and characteristics of the product. Thus, when properly designed and implemented, the control plan template can help in standardizing quality control measures and improving products and services.

What is a Control Plan?

To understand what a control plan is, it is necessary to mention the stages of its development. Usually, control plans are developed within the framework of the Advanced Product Quality Planning (APQP) and are preceded by the Process Failure Mode and Effects Analysis (PFMEA). In general, the control plan is a document, which defines controls to monitor and measure product and process characteristics. It also includes a reaction plan, which outlines the steps to be taken when a control fails. A control plan provides a clear understanding of what needs to be done at each stage of the pilot run or production to ensure that product and process control characteristics are met. It also specifies why and how control should be performed.

Benefits of Using a Control Plan Template

A properly designed control plan will provide the following benefits for the organization:

• standardize quality control

• prevent failures and defects

• enhance communication of requirements

• increase product and service quality

• ensure compliance with specifications

• serve as a training guide for employees

• facilitate continuous improvement.

Key Elements of a Control Plan Template

The control plan shall be applied throughout the production process, starting with receiving raw materials and ending with shipping the finished product. Usually, a control plan template contains the following sections:

1. General information

2. Process information

3. Product characteristics

4. Process characteristics

5. Reaction plan

6. Approval

Depending on the organization’s needs, the contents and design of the control plan may vary. Some control plan templates also include the following sections: special characteristics, responsible persons, product audit, and process audit.

1. General Information

The general information section normally contains the following information:

• part number or description

• process name or number

• supplier or customer

• date or revision number

• key contact information

2. Process Information

The second section of the control plan is process information. It contains a description of the production process, which normally consists of multiple steps. Each step is assigned a number (e.g., 10, 20, 30) and a name or description. In addition, the equipment involved in the process step is identified.

3. Product Characteristics

The third section lists the characteristics of the product, which shall be controlled. These characteristics are normally related to the special characteristics defined in the PFMEA. Each product characteristic should have the following information:

• name or description of the characteristic (e.g., hole diameter, length, material hardness, surface)

• specification or tolerance (e.g., 10.00 +/- 0.05 mm, Ra < 1.6)

• measurement technique or gauge (e.g., caliper, micrometer, vision system)

• sample size and frequency (e.g., 5 pcs per hour, 100% inspection)

• control method (e.g., statistical process control, poka-yoke, visual inspection, go/no-go gauge)

4. Process Characteristics

The fourth section lists the characteristics of the manufacturing process, which shall be controlled. Similar to product characteristics, each process characteristic should have the following information:

• name or description of the characteristic (e.g., molding temperature, welding current, cycle time)

• specification or tolerance (e.g., 200 +/- 5 C, 50 +/- 2 A)

• measurement technique or gauge (e.g., thermocouple, ammeter, timer)

• sample size and frequency (e.g., continuous, every shift)

• control method (e.g., automated process control, operator inspection)

5. Reaction Plan

The fifth section describes the reaction plan, which defines the actions to be taken when a failure occurs. The reaction plan should identify the persons responsible for taking actions and list the following details:

• stop the process or production

• isolate the nonconforming product

• notify the supervisor or quality engineer

• document the nonconformance report (NCR)

• initiate the corrective action process

6. Approval

Finally, the sixth section should include the signatures and approval dates of the persons responsible for reviewing the control plan. Usually, the control plan should be approved by the customer and the organization’s quality, engineering, and production managers.

How To Effectively Implement a Control Plan

In general, the control plan should be used throughout the pilot run and production to ensure that the specified process and product characteristics are controlled. In addition, the control plan should also be used for continuous improvement activities. Therefore, it is essential to provide proper training on the control plan and related procedures for all employees involved in the production process.

To ensure that all requirements are met when implementing the control plan, the following recommendations should be considered:

• use the control plan developed jointly by different departments (engineering, quality, production, maintenance);

• provide training for employees on the control plan procedures

• review and update the control plan at specified intervals (e.g., yearly);

• use PFMEA, statistical process control (SPC), and measurement system analysis (MSA) data when updating the control plan;

• periodically verify that the control plan requirements are followed.

Conclusion

A properly designed and implemented control plan template can be an essential element for improving product and process quality. By controlling key product and process characteristics, an organization can ensure that products conform to specified requirements and reduce the occurrence of defects and failures.