- INTRODUCTION
The purpose of this Control Plan methodology is to assist in the manufacture of quality products according to customer requirements. It does this by providing a structured approach to the design, selection, and implementation of value-added control methods for the entire system. Control Plans provide a written descriptive summary of the system used to minimize product / process variations. The intent of the Control Plan format shown in this section is to provide an example of how to document this information. An alternative format can be used as long as it contains at least the same information.
The Control Plan does not replace the information contained in detail in the operating instructions. This methodology applies to a wide range of manufacturing processes and technologies. The Control Plan is an integral part of a quality process and should be used as a living document. That is why this section should be used in conjunction with other related documents.
An important part of the quality planting process is developing a Control Plan. The Control Plan is a written description of a system for controlling parts and processes. A single Control Plan can be applied to a group or family of products that are produced by the same process at the same source. Drawings, as many as necessary, can be added to the Control Plan for illustrative purposes. In support of the Control Plan, instructions should be defined to monitor the process and use them continuously.
In effect, the Control Plan describes the actions required in each phase of the process including receipt, in process, outputs and periodic requirements to ensure that all outputs of the process are in a state of control. During regular production runs, the Control Plan provides process monitoring and control methods that will be used to control the characteristics. Since processes are expected to be continuously monitored and improved, the Control Plan reflects a strategy that is responsive to these changing process conditions.
The Control Plan is maintained and used throughout the life cycle of a product. Early in the product life cycle, its main purpose is to document and document the initial plan for process control. Subsequently, he guides manufacturing in how to control the process and ensure product quality. Finally, the Control Plan remains a living document, reflecting the current control methods and measurement system used. The Control Plan is updated as the measurement systems and control methods are evaluated and improved.
For process control and improvement to be effective, a basic understanding of the process must be obtained. A multidisciplinary team is established to develop the Control Plan using all the information available to obtain a better understanding of the process, such as:
- Process Flow Diagram System / Design / Process FMEA Lessons Learned from Similar Parts Team Knowledge of Process Design Review Optimization Methods (QFD, DOE, etc.)
The benefits of developing and implementing a Control Plan include:
| Quality
The Control Plan methodology reduces waste and improves the quality of products during design, manufacture and assembly. This structured discipline provides an evaluation through the product and process. Control Plans identify process characteristics and help to identify its sources of variation (input variables), which cause variation in product characteristics (output variables). |
| Customer Satisfaction
Control Plans focus resources on processes and products related to characteristics that are important to the customer. Proper placement of resources at these critical points helps reduce costs without sacrificing quality. |
| Communication
As a living document, the Control Plan identifies and communicates changes in Product / Process characteristics, control methods and measurement characteristics. |
