Control Plan Manufacturing | Control Plan Quality

The Control Plan is a written document that describes the methods & processes needed for controlling the manufacturing of products (starting from raw material procurement to finished product shipment).

The Control Plan Quality gives the operator or inspector the knowledge necessary for proper process control and the production of high-quality components or products.

A Control Plan is one of the important documents of the Production Part and Approval Process (PPAP).

Process Flow Chart (PFC) & Process Failure Mode Effect Analysis (PFMEA) are the most important documents/elements of PPAP, and both are the direct source of inputs for making the control plan.

It is very important to note that the process/operation sequence number of the control plan should be aligned with the PFC & PFMEA sequence number.

Control Plan is a living document that should be periodically reviewed & updated for the following cases:

• Implementation of corrective actions against customer complaints, when applicable.
• When there is any change occurs that affects products, production process, measurements, supply chain, & failure mode effect analysis (FMEA).
• At a frequency defined according to customer requirements or based on risk analysis.

Control Plan Definition

Definition as per IATF 16949: Control Plan is the documented description of the systems and processes required for controlling the manufacturing of products.

Types of Control Plan | Phases of the Control Plan

A control plan is prepared in three phases:

• Phase 1- Prototype Control Plan
• Phase 2- Pre-launch Control Plan
• Phase 3- Production Control Plan

Prototype Control Plan:  Prototype control is a description of dimensional measurements, material, and performance tests that will occur during prototype development. The organization shall have a prototype control plan if required by the customer.

Pre-launch Control Plan: Pre-launch control plan is a description of dimension measurements, materials, and performance tests that occur after the completion of prototype phase and before regular production begins.

Pre-launch is defined as a production phase in the process of product realization that may be required after prototype build.

Production Control Plan:  This level of control plan includes a complete listing of the product and process characteristics, the process controls, tests, and measurement systems that occur during mass production or routine production.

Control Plan Format | Control Plan Elements

A control plan quality format includes the following general data/contents/elements: 

1. Control Plan Phases (Prototype, Pre-Launch, Production)
2. Control Plan Number
3. Issue date and revision date, if any
4. Part Number(s)
5. Core Team or CFT
6. Part Name/Description
7. Latest Engineering Change Level
8. Key contact
9. Organization’s name/Plant or site designation
10. Functional area responsible
11. Part/process step number
12. Process name/operation description
13. Machine, Device, Jig, Tools for manufacturing etc.
14. Product control characteristics: Includes product & process description with reference number – a)  Number b) Product c) Process
15. Classification- symbols used for special characteristics that are critical to quality (CTQs), & critical to process (CTPs).
16. Methods: A system or methods (includes inspection methods & tools, procedures, and work instructions etc.) for controlling the products and processes.
17. Product/Process Specification/Tolerance
18. Evaluation/Measurement Technique
19. Sample Size & Frequency
20. Control Method: The control methods includes but are not limited to visual inspection, SPC, mistakes proofing,  data collection etc.
21. Reaction Plan: includes action plans (containment & corrective actions) against the nonconforming products & avoiding re-occurrence.

Control Plan Key Points

The organization shall address the following key points while making the control plan for the manufacturing of quality products:

• The Control Plan (CP) includes all process stages from receiving to shipping.
• The Control Plan steps are keyed to the Process Flow Chart and FMEA sequence numbers.
• All special characteristic identification and technical requirements are met in the Control Plan.
• The CP includes, or references, the relevant process control parameters.
• The CP includes error-proofing as appropriate.
• The CP includes suitable sample sizes and frequencies.
• The CP is subject to periodic review and update.
• The control plan includes the reaction plan for what to do if a non-conformance is found.