Control methods - What exactly are 'control methods' in a Control Plan

[Quality Man]

I am currently developing a control plan and am getting confused as to what exactly are control methods. Are they items such as operator log sheets, first off sheets, etc.... or are they more likely to be such items as work instructions/procedures ?Thanks

 

[Marc]

A work instruction could be. Another example would be a dimensional check every <insert time period>.

Basically a control method is what you do to lower the risk of an 'event' occurring and/or becoming an escape point for a given potential 'failure'. The control plan is comprised of customer / internal critical characteristics as a minimum. Just ask yourself what you do to keep something from happening and identifying it if it does occur.

If you want to give an example characteristic, maybe we can comment on potential controls.

 

[Wes Bucey]

I am currently developing a control plan and am getting confused as to what exactly are control methods. Are they items such as operator log sheets, first off sheets, etc.... or are they more likely to be such items as work instructions/procedures ?Thanks

Here's an excerpt from a "Control Plan Procedure" I created some time ago. It should give you some insight into what you want to achieve in your own Control Plan.

1 .0 Introduction/Objective/Purpose:

The purpose of this procedure is to provide a system and instructions for creating a unique Control Plan for each product manufactured. The Control Plan thus created is one of the Work Instructions associated with that part.

2.0 Application:

This procedure applies to all parts produced by the organization. The procedure directly concerns the Design and Production departments. All other departments are indirectly concerned as they have input or output to or from the production process.

3.0 Procedure:

·[font=&quot] [/font]The Design Department plans a method of producing a part in conjunction with the Production Department which addresses all applicable aspects of controlling and recording the manufacturing process from raw material through finished product, inspection, installation, and subsequent servicing.

·[font=&quot] [/font]The process may involve several or all departments, ranging from purchasing, to administration, to quality, to sales, and may include the customer.

·[font=&quot] [/font]Typically, the designer determines the critical characteristics of the finished part. In conjunction with production department, the design team determines whether production department has capability and capacity to build the product and what equipment and personnel categories are necessary.

·[font=&quot] [/font]At this stage, inspection criteria are developed which involve quality department which determines if it has equipment and expertise to perform the inspections.

·[font=&quot] [/font]If capacity and capability are acceptable, project manager may order prototypes which may or may not be made on production equipment. Test and inspection methods are used on prototypes.

·[font=&quot] [/font]If all is satisfactory, Control Plan provides for production piece and First Article inspection. During the production of First Piece, evaluation proceeds on in-process inspection plans.

·[font=&quot] [/font]Project teams ensure design output requirements are documented and verified against input requirements. These documents may include, but are not limited to

·[font=&quot] [/font]Specifications

·[font=&quot] [/font]Test plans

·[font=&quot] [/font]Schematic diagrams and parts lists

·[font=&quot] [/font]Other necessary documents

·[font=&quot] [/font]Specific adherence to regulatory requirements

·[font=&quot] [/font]We identify design and production output requirements as part of the production process. Responsible team members review output documents and products for conformance and accuracy before release as part of design review.

·[font=&quot] [/font]All stages of the process are subjected to constant review and evaluation throughout the production cycle.

·[font=&quot] [/font]If in-house capacity and capability is insufficient, the Control Plan is extended to suppliers and subcontractors who can fill the gaps. The Quality System approves suppliers before production can begin.

 

[Quality Man]

Thanks

Thanks for the input from all. This was my first time visiting the site and I have found it to be a valuable tool. I'll visit frequently. Thanks again......

 

[1killercls]

Thanks for the input from all. This was my first time visiting the site and I have found it to be a valuable tool. I'll visit frequently. Thanks again......

Welcome!

 

[Bill Ryan - 2007]

Another example would be a dimensional check every <insert time period>.

This would actually be place in the "Sample size/frequency" column(s).

FWIW - I address the "Control Method" as the means the operator/process is told/trained to perform the intended inspection/verification - could be a procedure, work/operator/inspection/setup work instruction, "automated poka-yoke", TPM instruction, SPC charts, etc.

From page 43 of the APQP manual: "This column contains a brief description of how the operation will be controlled, including procedure numbers where applicable..... Operations may be controlled by, but are not limited to, Statistical Process Control, inspection, attribute data, mistake-proofing, (automated/non-automated), and sampling plans........"

 

[fuzzy]

Agree with Bill 100%

This is how I also have approached this column for 10+ years without a problem. It just struck me that the overarching circular reference could be that the "control plan" is a "control method". My mind is working funny today