Professional Documents
Culture Documents
Understanding Control Plans
Understanding Control Plans
Methods Section
The information contained in the methods section includes the specification to be measured and a plan for
collecting the data and controlling the process. The data could be variable or attribute data.
23. Product/Process Specification / Tolerance – List the specification and tolerance as defined on the
drawing, material specification, 3D model or in the manufacturing or assembly documentation
24. Evaluation/Measurement Technique – Identify the measurement tools, gages, fixtures and / or test
equipment used to evaluate the part or process specification listed in the previous column.
A Measurement Systems Analysis (MSA) is recommended to assure that correct, consistent usable
data is being collected.
25. Sample Size – If sampling is required, list the corresponding sample size or number of parts or
assemblies that should be measured /evaluated during the process
26. Sample Frequency – If sampling is required, list the frequency at which the samples will be taken
during the process. As an example, the frequency could be 1st, 25th and final, or it could be
continuous.
27. Control Method / Prevention – This column should list the prevention controls and / or documents the
operator will need to complete the process step. This should include work instructions, drawings, visual
aids, etc.
28. Control Method / Detection – The information in this column is critical for the effectiveness of the
Control Plan. This column should list any detection controls determined by the team during the
previous quality plan activities, including the DFMEA and PFMEA. The methods could include but are
not limited to Statistical Process Control (SPC), visual inspection, attribute data collection, error
proofing, etc. A document or procedure number may also be populated in this space. The effectiveness
of the control selected should be evaluated on a regular basis.
29. Reaction Plan – This column should specify the actions required to prevent production of non-
conforming products. The actions should be the responsibility of the operator and / or their immediate
supervisor. They should include at the very least how to label, identify and quarantine the non-
conforming material and the proper disposition of the suspect material, parts or assemblies. In addition,
the reaction plan should include directions for properly documenting the incident and who should be
notified of the non-conformance.
Control Plans can vary depending upon what type of process is being controlled. There are many different
applications where the Control Plan can add value to the process. Below are a few examples of the different
applications:
Equipment set-up process where the major contributor to process variation is proper set-up of the
equipment prior to the production run
Equipment tooling dominant process where the major influence on variation is the impact of tool life
on the part or product design characteristics
Operator dominant process where the variation in the process is a result of the knowledge or training of
the operator and the proper controls
The Control Plan can be a very effective tool for reducing the amount of scrap generated by a process. It can be
very useful at improving quality and helping contain any non-conforming product prior to it leaving the work
cell. It is most effective when incorporated into a larger quality plan. The Control Plan is the same as any other
tool, in that to get the most value you must know how to use it properly. Your teams will require training and
coaching in order to implement an effective Control Plan system. If you are interested in learning more about
Control Plan Methodology, please contact one of our experienced professionals at Quality-One.