Guide to Control Plans for CCDS

JLR-HTG-119188 Effective Date: 18/09/2017

Issue Level 1 Next Review: 18/09/2018
KWS

Guide to Control Plans for CCDS

Objective: To provide a guide to the JLR requirements for Control Plans to be developed by our
suppliers/manufacturers and reviewed by the JLR Engineering & STA team. These requirements are
based on the industry APQP standard governed by the AIAG and part of IATF 16949 which all our
suppliers are subject to.

Scope: All parts supplied to JLR to support any prototype, pre-production or production build
must have a Control Plan that has been reviewed and agreed by JLR as per the APQP deliverables
(JLR-HTG-122809).

How Control Plans fit with other activities

The model below describes the relationship between the Control Plan and other important
elements of Excellent Engineering and the requirements of APQP.

When reviewing a Control Plan the JLR Engineer/STA must consider all the elements grouped in
red. They should be knowledgeable of the manufacturing process, satisfied that a thorough Process
FMEA has been conducted by the manufacturer and be in agreement with the Special
Characteristics documented on the Special Characteristic Summary Sheet (SCSS). When the
reviewer is satisfied with these pre-requisites they should proceed to look at the Control Plan.

A control plan checklist is also available in the JLR Way (JLR-CHK-119028).

An example format for a control plan is also available in the JLR Way (JLR-SPL-37045).

Prototype Build Control Plan (Typically for M1 Build)

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)
Guide to Control Plans for CCDS
JLR-HTG-119188 Effective Date: 18/09/2017
Issue Level 1 Next Review: 18/09/2018
KWS

Prototype control plans are a description of the dimensional measurements, material

measurements and functional tests that will occur during prototype build. At this stage in the
development the focus of control is on the physical product and less so on the process. The
manufacture of prototype parts provides an excellent opportunity to gain early process learning
that will inform the production process and later Control Plans.

It is the supplier’s responsibility to review prototypes for the following:

 Assure that the product meets specification and report data as required.
 Ensure particular attention is given to special product and process characteristics.
 Use data and experience to establish preliminary process parameters and packaging
requirements.
 Communicate any concerns, deviations and/or cost impact to the customer.

Control Plan methodology is described on page 3 below.

The Control Plan Checklist (JLR-CHK-119028) will assist preparation of the control plan.

Pre-Production Control Plan (Typically for VB Build up to Run @ Rate)

Pre-Production Control Plans build upon the Prototype Control Plan, which focused on output
measurements, by including additional process controls. The Pre-Production Control Plan is used
until the production process is validated and the Production Control Plan is in effect. The purpose of
the Pre-Production Control Plan is to contain potential non-conformities during or prior to initial
production runs. Examples of enhancements in the pre-production control plan are:

 More focus on process inputs/parameters/characteristics

 More in-process and final check points
 Robust statistical evaluations
 Enhanced audits
 Identification of error-proofing devices.

Control Plan methodology is described on page 3 below.

The Control Plan Checklist (JLR-CHK-119028) will assist preparation of the control plan.

Production Control Plan (From Run @ Rate onwards)

The production control plan is a written description of the systems for controlling production parts
and processes. The production control plan is a living document and should be updated to reflect
the addition or deletion of controls based on experience gained by producing parts. The production
control plan is a logical extension of the pre-production control plan. Mass production provides the
organisation the opportunity to evaluate output, review the control plan and make appropriate
changes. The Production Control Plan should have far more focus on controlling the process and its
inputs rather than measuring the physical outputs as was the case in earlier iterations of the control
plan.

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)
Guide to Control Plans for CCDS
JLR-HTG-119188 Effective Date: 18/09/2017
Issue Level 1 Next Review: 18/09/2018
KWS

Control Plan methodology is described on page 3 below.

The Control Plan Checklist (JLR-CHK-119028) will assist preparation of the control plan.

Control Plan Methodology

A fundamental step in the process for quality planning is the development of a control plan. A
control plan is a written description of the system for controlling parts and processes. A single
control plan may apply to a group or family of products that are produced from the same process.
Drawings and visual standards, as necessary, may be attached to the control plan for illustration
purposes. In support of a control plan, operator and process monitoring instructions should be
defined and used continually.

The control plan describes the actions that are required throughout the process including receiving,
in-process, out-going and periodic requirements to assure that all process outputs will be in a state
of control. The control plan will also include as necessary the measurement and testing of the parts
produced from the process.

The control plan is maintained and used throughout the product lifecycle. During production runs,
the control plan provides the process monitoring and control methods that will be used to control
characteristics and provide data which will feed continuous improvement activities. The control
plan remains a living document, reflecting the current methods of control and measurement
systems used.

For process control and improvement to be effective, a good understanding of the process must be
obtained. A cross-functional team must develop the control plan by utilising all the available
information:

 Process Flow Diagram

 System/Design/Process Failure Mode & Effects Analysis
 Special Characteristics
 Bill of Process (Standards)
 Lessons Learned
 Design Reviews
 Optimisation Methods (QFD, DOE, Robust Engineering, etc.)

The control plan discipline provides a thorough evaluation of product and process. Control plans
identify process characteristics and identify the control methods for the sources of variation which
ultimately cause variation (dissatisfaction) in the product characteristics experienced by our
customers. A good control plan should focus on delivering products and processes that meet the
requirements of the customer.

Process Analysis
An effective control plan requires a detailed and thorough analysis of the sources of process
variation and the influence they have upon the product. Tools that may be used include:

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)
Guide to Control Plans for CCDS
JLR-HTG-119188 Effective Date: 18/09/2017
Issue Level 1 Next Review: 18/09/2018
KWS

 Fault Tree Analysis

 Cause & Effect (Machines/People/Methods/Materials/Measurement/Environment)
 Robust Engineering
 Design of Experiments

Different types of process present different challenges for control and reduction of variation. To
assist analysis it can be useful to review some of the following examples. The team should not limit
their thinking to just one ‘process type’ but should always consider the influence of
Machines/People/Methods/Materials/Measurement/Environment.

Set-Up Dominant Process: The process is highly capable and stable, therefore set-up is a major
variable impacting product variation.

Plastic injection moulding. After setup of the mould, the machine must be adjusted to produce a
dimensionally & cosmetically good part. The moulding process is highly repeatable because all the
parameters are specified on a setup card and are computer controlled. After setting the machine a
sample part is produced which is visually inspected and key dimensions for fixings/interfaces are
checked using a checking fixture and gauges.

 Capability studies on the product characteristics show that when properly set-up, the
process is highly capable and stable. The set-up specifications become the process
characteristics that affect the product characteristic.
 Types of controls for the process characteristic include first piece check procedures and
verification that machine settings are correct to authorised set-up cards.
 Product characteristics are measured to ensure the set-up is correct and that no special
cause has occurred. Lot control may be appropriate between checks.

Machine Dominant Process: Machine parameters are the variables affecting process output.

Circuit board with soldered electronic components. Properly soldered connections are the major
product characteristics. Two major process characteristics for the wave solder machine are solder
level and flux concentration. An automated feeder controls the solder level by sensing the level of
solder and feeding in additional solder as the level is reduced. The flux must be sampled and tested
for the concentration level. The Special Product Characteristic is measured 100% by checking
electronically for continuity.

 Machine settings are the process characteristics that need to be controlled.

 Types of controls include self-adjusting devices on the parameters and statistical
measurements taken on the process parameters (e.g. X-Bar R charts).
 Product characteristics are measured using error proofing or statistical sampling.

Fixture/Pallet Dominant Process: Fixture-to-fixture variation causes product variation.

Metal castings are loaded on a seven-stage rotary machine with several fixtures which the rotary
machine rotates under a cutting head. There is a machined surface where depth of cut and

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)
Guide to Control Plans for CCDS
JLR-HTG-119188 Effective Date: 18/09/2017
Issue Level 1 Next Review: 18/09/2018
KWS

perpendicularity are significant product characteristics. Besides the cutting tool, the removal of
debris and proper adjustment of fixtures can significantly affect the product characteristic.

 Process characteristics include variation between fixtures or pallets. The dimensional

differences between fixtures or pallets and part location contribute to product variation. In
addition, debris accumulated on the fixture can cause fixture-to-fixture variation of part
location.
 Types of controls for fixture/pallet process characteristics are driven by loading procedures,
fixture/pallet adjustments and maintenance (i.e. cleaning).
 Product characteristics are often difficult to measure in fixture/pallet dominant processes.
Therefore, frequent statistical product sampling may be required for Special Product
Characteristics.

Tooling Dominant Process: Tool life and design characteristics are the variables affecting the
process output.

A sheet metal die is used to form a steel bracket that has several angles and a pierced hole. The
pierced hole diameter will not vary significantly; therefore it is not marked as a Special
Characteristic. The presence of the hole is critical to the part. The angles on the part are critical and
two angles are marked as Special Characteristics. Historically, broken hole punches are a problem
with this type of tooling. Further, moving parts in the tool can vary when forming the angles in the
bracket.

 The process characteristic is the tooling. Tools can have details that break or moving parts
that intermittently/permanently fail to move. Tools can also wear or be repaired incorrectly.
The product characteristics are affected by these tooling problems.
 Types of controls for tooling dominant processes are mainly seen in the product. First piece
check can verify that a tool has been properly repaired. When in operation a tool failure may
go unnoticed except in the part, therefore lot control is appropriate. Error proofing
techniques that check for holes or a dimension are also needed.
 Product characteristics are a very important measure of proper tool life performance.

Operator Dominant Process: The system is sensitive/dependent upon operator knowledge and
control.

Headlamp aim is one of the final operations during car and truck assembly. Proper headlamp aim is
a legal requirement and therefore a Special Product Characteristic. The operator adjusts an aiming
device attached to the headlamps until two bubble levels centre with each other. The Special
Process Characteristic is operator knowledge and skill to ensure the two bubble levels centre during
aiming. This type of process would be an obvious target for automation if the manual process is
proven not to be capable.

Material or Component Dominant Process: Characteristics of materials/components are the

variables affecting the process output.

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)
Guide to Control Plans for CCDS
JLR-HTG-119188 Effective Date: 18/09/2017
Issue Level 1 Next Review: 18/09/2018
KWS

A car roof made of SMC. SMC is a molding compound that is temperature sensitive, has a specific
shelf life and for which mixing is critical. The parts produced from this material can become brittle
when the material is improperly mixed, handled or rotated. A force specification on one end of the
part is a Special Product Characteristic. The Special Process Characteristics are the proper
formulation, storage and use of material date control. Material controls would include a laboratory
report on each lot of compound and that lots are dated for proper rotation.

Preventative Maintenance Dominant Process: Equipment maintenance is the main variable that
affects the process output.

A painting operation for decorative parts requires clean equipment and a dirt-free work area. Dirt-
free paint is a Special Product Characteristic. Periodic cleaning of the paint equipment and paint
room prevents the problem of dirt in the paint. The process characteristic is a scheduled routine
cleaning, repair, calibration and replacement. Types of controls for these process characteristics
included scheduled maintenance programs and warning devices for monitoring. Product
characteristics are checked after maintenance to verify the process is.

Climate Dominant Process: Climate variables such as temperature, humidity, noise and vibrations
have major impact on the process outputs.

Humidity adversely affects the function of plastic injection molding machines. Plastic material
absorbs water from the air, causing defects in the molded part. Material dryers are installed on the
molding machines to eliminate the problem.

 The proper functioning of the dryer is the process characteristic.

 Control for this process characteristic is a planned, periodic check to make sure the dryer is
turned on and performing correctly.
 Product characteristics are checked by visual examination during first piece check and by
subsequent periodic checks.

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Author: Andreea Stana (astana1) Owner: Craig Phillips (cphilli7)