Accordingly, this manual and format, approved and endorsed by chrysler, ford. Sketches, as necessary, may be attached to the control plan for illustration purposes. How to use a control plan for six sigma villanova university. This methodology is applicable to a wide range of manufacturing processes and technologies. Application off control plan ppap tool in automotive industry production. The purpose of this document is to provide the project manager, sponsors, steering committee members and all other stakeholders with the standard process for managing changes on the project name project. A control plan is a written description of the system for controlling parts and processes. This free ebook shows importers who are new to outsourcing production to china. In the case of this control plan, a subgroup of five samples is pulled hourly and checked with a gonogo functional gage. Have all the controls identified in the pfmea been included in the control plan. A typical process control plan can contain six sections that record essential process details. Control plan definition control plan n a process management tool used to identify and monitor the activities required to control the critical inputs and key outputs for a process, so the process will continually meet its product or service goals.
Use the process control plan to focus on the xs the inputs to the process. Howto guide control plans quality control plan, excel. The process control plan is your companion to the process management summary. In order to implement iatf 16949, the organization needs to develop control plans at the system, subsystem, component, andor material levels for the relevant manufacturing site and all product supplied what is a control plan and when is it used. Implementing a six step control plan for six sigma. For example, you may want to add additional columns to include information such as the method and equipment used for inspection. An example of a quality plan is a manufacturing company that machines metal parts.
Such plans may take many different forms depending on the outcome they are to produce. Process step control method reaction plan champion. T able 2 shows an example of a control plan developed during. When making the control plan, keep in mind that all the process, tests and other important materials should be determined. Unless the underlying process capability for screw depth is outstanding six sigma cpk of 2. Control plan template example in excel sanzu business training. Control plans are used in industry in everything from automotive to healthcare. Area all special productprocess characteristics included in the control plan. A control plan lists all product and process inspection points required to deliver a defectfree outcome, and is essential for maintaining process control over the long run related.
The actual plan itself is a subsidiary plan or a component of the project management plan. More frequent inspection more inprocess and final check. Were dfmea and pfmea used to prepare the control plan. To aid the manufacturing of quality products by using a structured approach to identify and implement valueadded controls to minimize process and product variation. Sep 18, 2018 this is where the control plan comes in. How to integrate fmea, control plan, spc and capa datalyzer. Example of free form note if the cause list is not providing the exact cause. A six sigma process has a sigma level of six, and for all practical purposes is considered a defectfree process over the long run, provided that adequate controls are in place to maintain capability. They are a widely adopted method of ensuring that the process produces the output required to the right quality. While the control plan example on this page is manufacturing related, the same concept can be adapted to any number of physical or transactional work processes.
A control plan is a document containing the procedure or the methods to. It provides answers to essential questions concerning time. Process name operation description machine, device, jig, tools for mfg. Part process number process name operation description machine, device, jig, tools for mfg. Additional interventions, rationales and steps should be added pursuant to your facilitys final plan of care, following standard nursing practice, other approved internal policies and procedures, and universal precautions. Process failure mode and effects analysis, that will ensure product quality in the manufacturingassembly. This control plan template has a theme that can be effectively used to display a large gamut of information details relevant to any particular business process or. To aid the manufacturing of quality products by using a structured approach to identify and implement valueadded controls to.
The following is an example of a quality assurance quality control qaqc plan for continuous emissions monitoring systems or cems. A control plan is a living document that outlines the methods taken for quality control. There are many variations of the form used to document the control plan. The purpose of the control plan is to control the process and reduce the opportunity for deviation. For example, you may want to add additional columns to include information such as. Supplier to enter reaction plan corrective action process. Control plan example control plan page of prototype control plan number prelaunch production key contactphone date orig. By the final stages of a six sigma project, your team has solved the major problems in the specified process. Quality plans may also be represented by more than one type of document to produce a given outcome. And remember, this example is a manufacturing example. Please note that the opb may require the submission of additional information to augment an op or to explain issues identified during the analysis of the op and other budget request. How to create a six sigma control phase plan dummies.
A document control plan is an essential component of the project plan that guides the project team regarding the control of documents, including their creation, version control, retention, and other important issued related to documentation. This plan template in pdf has all the possible components of a great software quality control plan. Defining the action plan if the control plan for the process step is adequate, no further action required typically if rpn value is control is the function that checks whether the software project follows its standards processes, and procedures, and that the project produces the desired internal and external deliverable products i. The team should use a control plan to ensure that the process does not slip back into the ways of the old process. Project management process plans this section of the project management plan specifies the project management processes for the project. The contractor quality control plan is ideal for contractors looking for quality control plans. How to fill out a process control plan to raise product quality. A process control plan pcp is a summary of defect prevention and reactive detection techniques.
Pdf this article presents the theory and practice of automatic process control and instrumentation, outlining basic concepts of automatic control. Click on this icon to open the cooper industries ppap forms kit which is attached to this pdf manual. The intent of the control plan form displayed in this section is to provide an example of how this information can be documented. Production this level of control plan should contain a comprehensive listing of the product and process special characteristics, the process controls, measurement methods and tests that will be performed during regular production. Change control process university of california, berkeley.
Control plan template in excel to minimize variation. This control plan template is a microsoft excel document that you can use and modify to suit your specific needs. Part numberlatest change level core team customer engineering approvaldate if reqd. Through this system of monitoring and control, customer requirements will be met and the product or process variation will be reduced. In making a control plan there are things that you need to remember. This is a weak process control step and would produce a. Rma process xxx notify production of new delivery date. It can easily be modified to include additional sections if desired. The results are then plotted on a pchart, which is a percentdefectives spc statistical process control chart. The start of process improvement is creating the flow chart and fmea for the. Area all special product process characteristics included in the control plan. This qaqc plan meets the minimum requirements of the indiana state rule 326 iac 354 standard operating procedures and chapter 20 of the indiana quality assurance manual.
October 7, 2009 compliance to other specific dbs or customerregulatory requirements eg. Well, the control plan is the document that sets out what makes up the quality system. A single control plan may apply to a group or family of products that are produced by the same process at the same source. This includes human resources and training requirements, actions that should be taken if measures are outside the specified range, and reactions needed to ensure process owners sustain the gains of process improvements. Operational plan format, guidelines, and instructions 3 the operational plan components and guidelines discussed in this document are basic, generic requirements. Sample size the number of part or process samples taken to check from. Process failure mode and effect analysis apb consultant. Pfmea audits, control plan audits, production part approval compliance audits, and preventive maintenance audits. The control plan helps assure quality is maintained in a process in the event of employee turnover by establishing a standard for quality inspection and process monitoring. This is a weak process control step and would produce a high riskprioritynumber on a pfmea. A control plan deals with the same information explored in a fmea plus more. Operational plan format, guidelines, and instructions for fy. The major additions to the fmea needed to develop a control plan are.
In this step, you need to schedule the quality control activities to ensure that the project is as per the quality levels. Supplier quality management production part approval. Process specification tolerance evaluation measurement technique sample control method 0 receive packaging e utility 6 inspection no defects compare to shipper per. The template in word format is a form that consist of the project name and project number. Make sure the problems remain solved with safeguards that keep the improved process functioning as. The same technique can be applied to any process services industry, backoffice, transactional processes.
The scope of the project name has been defined in the approved project charter. A nonexistence, unrealized or improper document control plan, will create disorderliness in the project team that may seriously affect the business. The purpose of this template is to define the techniques, procedures, and methods that should be used by your organization to assure ontime delivery of the software that meets all specified requirements with the given project resources. A control plan is a document describing the critical to quality characteristics, the critical xs or ys, of the part or process. Control plans are living documents that should be periodically updated as the measurement methods and controls are improved throughout the life cycle of the product. But you can place process outputs, the y the ctqs, on a process control plan, too. All the steps in the manufacturing process that are relevant to the control of the product quality. Howto guide the following steps can be used in developing a control plan. Process failure mode and effects analysis, that will ensure product. Part numberlatest change level core team customer engineering approvaldate if reqd part namedescription supplierplant approvaldate customer quality approvaldate if reqd. Control plans must have all the phases present in the business plan in pdf. Dmaic tools the proven method for process improvement. Control plan template continuous improvement toolkit.
No project can be considered complete until it is supported by a control plan. The form is undersigned by the quality control manager, project manager, project superintendent,electrical foreman,mechanical foreman and the civil foreman. The overall intent of the pcp is to control the product characteristics and the associated process variables to ensure capability around the identified target or nominal and stability of the product over time. An alternate format may be used as long as it contains the same information, as a minimum. Pdf application off control plan ppap tool in automotive.
This step requires you to pick a method as well as the necessary resources to meet the quality of the project. Quality control plan project quality control plan 1. The control plan template is a typical excel document which would help people to list the product and its characteristics. Advanced product quality planning and control plan reference manual. Was the control plan developed according to the methodology described in chapter 6 of the apqp manual. This section of the plan records key information to identify the process and the process owner. Notify supervisor supplier to enter approvers signature. Hardly any text book explains how fmea, control planning and spc can be. A quality control plan helps in keeping in check the rate of quality of the products and services, and also the quantity you provide that makes you different and unique from the others. A six sigma control plan can be displayed on a simple table. Pdf production part approval process, known as ppap, is a. Defining the action plan if the control plan for the process step is adequate, no further action required typically if rpn value is 9145. May 05, 2016 a control plan is a written summary that describes what is needed to keep an improved process at its current level.