Control Plan Content Requirements - Level of Detail

W

Willie

#1
a Control Plan should describe all actions necessary including receiving, in-process,out going and periodic requirements to ensure that all process outputs will be in a state of control.
According to myself all controls necessary to ensure the successfull execution of a Process Function or Operation should be included in Control Plans.

A Colleague tends to differ from me...according to him you only need to identify key product characteristics and their related key process issues in a Control Plan and forget about all other issues such as incoming inspection of material, storage, packaging or movement of product. This implicate that a process with no final product characteristics will for example not need any control actions in the Control Plan.
According to him the incoming inspection system will for example take care of incoming inspection requirements and the 10 other systems will take care of the other aspects.....it is therefore not necessary to incude these in the Control Plan.

I do not agree with his approach.

Question ...will his approach be acceptable and be regarded as compliant to the requirements of QS 9000 or not ????.
 
Elsmar Forum Sponsor
L

Laura M

#2
Dock to Dock PCP's were recommended by our registrar (when I worked for a large company), but I don't think its that cut and dry. Most receiving Inspection controls just referred to the appropriate receiving procedures. When you start looking at failure modes (PFMEA) that can happen in transit from dock to assembly line, etc, in some cases you may prevent defects from getting through your process.
We definately included more than KPC's, however, I do think the APQP manual is vague in this regard. Others?
 

Marc

Hunkered Down for the Duration
Staff member
Admin
#3
Typically a control plan contains customer defined Key Product Characteristics as a minimum, plus any characteristics you decide are important or critical to your process(es) or the product.

The question becomes how far do you go. Your customer may specify 4 Key (or Critical or Special - different companies call them different things) Characteristics. Typically these are defined on the print. Ford uses the infamous 'inverted delta', for example, to identify 'critical' characteristics.

Now it's your turn. You look at areas such as receiving, etc. through delivery. What do you think is critical? You should have input from an FMEA to help you determine your critical characteristics. As is always the case, you're looking at risk factors with your FMEA.

'Legally', your colleague is right saying: "...you only need to identify key product characteristics and their related key process issues in a Control Plan..." However, related key process characteristics may include aspects of everything from receiving to delivery.

"...This implicate that a process with no final product characteristics will for example not need any control actions in the Control Plan..." True - but try to convince an auditor that there are no key characteristics at all. I have seen plenty of products with no customer defined Key Characteristics at all (less so now than 5 years ago because of QS). I have not (in some years) seen a product with no control plan entries.

What receiving does is, in fact, a result of a determination of your identified key characteristics. You may not be thinking of it in the sense of a control plan, but you have receiving requirements for materials and such (including items which go into the product as well as items used to process the product) which have the same basic elements. Sample size, reaction plan, etc. For all intents and purposes receiving does have a control plan. Even in the case of 'ship to stock'.

Your colleague is focusing only on his part of the pie, maybe?

A good question to ask here is: Do you have a Receiving FMEA?

"...and the 10 other systems will take care of the other aspects..." What are the 10 other systems?
 

Marc

Hunkered Down for the Duration
Staff member
Admin
#4
Please replace the wording "Key Product Characteristics" in my posting of 22/5 with "Customer defined Key Product Characteristics"

I will appreciate more comments.
Thanks to Marc and Laura

Willie
 
Q

qualityboi

#5
The appendix on page 79 of the APQP blue book has a reference checklist that indicates control plans and the need to address incoming through packaging. Are there any harder requirements in the blue books / ISOTS 16949 that cite having a the control plan address incoming materials through packaging directly.

I already realize the logic in having them, but the point is that an auditee is challenging me to cite the specific requirement.

I am new to auditing FMEAs and Control plans, yes I have already had training...
 

Raffy

Quite Involved in Discussions
#6
Hi everyone,
Is the control plan attached in the 2nd edition APQP Manual was changed? What are the changes? Please advice. A revised control plan attachment is highly appreciated.
Thank you very much in advance for the usual prompt attention you will give in this request.
P.S.
I already requested to purchase the said Reference Manual, but i haven't heard any approvals yet... :( I am currently updating our control plans in preparation for our TS16949 Surveillance Audit probably by June 2009. - Thanks in advance...
Best regards,
Raffy
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#7
a Control Plan should describe all actions necessary including receiving, in-process,out going and periodic requirements to ensure that all process outputs will be in a state of control.
According to myself all controls necessary to ensure the successfull execution of a Process Function or Operation should be included in Control Plans.

A Colleague tends to differ from me...according to him you only need to identify key product characteristics and their related key process issues in a Control Plan and forget about all other issues such as incoming inspection of material, storage, packaging or movement of product. This implicate that a process with no final product characteristics will for example not need any control actions in the Control Plan.
According to him the incoming inspection system will for example take care of incoming inspection requirements and the 10 other systems will take care of the other aspects.....it is therefore not necessary to incude these in the Control Plan.

I do not agree with his approach.

Question ...will his approach be acceptable and be regarded as compliant to the requirements of QS 9000 or not ????.
I agree with you. The control plan should be....well, the control plan. Every characteristic you check, how you check it, with what gage, how often and what do you do if you do not meet the specification should be in this plan for everything you expect to check. Why have a separate system for incoming receiving inspection? Now, if the incoming part is a sublevel BOM with its own part number, then, yes, it should have its own control plan AS the incoming inspection plan. The assembly control plan just brings in the part, maybe with a label verification.

So many people keep trying to reinvent a pretty darn round wheel...:rolleyes:
 
V

Varadarajan

#8
I agree with you. The control plan should be....well, the control plan. Every characteristic you check, how you check it, with what gage, how often and what do you do if you do not meet the specification should be in this plan for everything you expect to check. Why have a separate system for incoming receiving inspection? Now, if the incoming part is a sublevel BOM with its own part number, then, yes, it should have its own control plan AS the incoming inspection plan. The assembly control plan just brings in the part, maybe with a label verification.

So many people keep trying to reinvent a pretty darn round wheel...:rolleyes:



I too agree.

My experience in a precision components manufacturing (TS) company for Bosch customer (For Hydraulic gear pump covers)

We had control plans with all the process from Receiving inspection of castings,CNC,VMC etc..vibro deburing,Surface treatment, to Final Packing .
The Receiving inspection has important features of casting/Metallurgical properties.

The final Packing also has specific customer requirements as how many components in a Box, and how many rows it should be placed and in anti-corrosive sheets or bags etc(The parts are shipped by sea)

So all the important features or dimensions affecting the final product must be controlled.
The control plan tells us the control methods for all the non-conformances.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#9
Some folks thought that the washes could be skipped over in the control plan - because no dimensions were changing. But a lot of nonconformances came from not controlling the cleanliness of the wash fluid, or the concentration of the solvent or detergent. Finally convinced them that every step needs to be on there!:read:
 
P

prototyper

#10
a
Question ...will his approach be acceptable and be regarded as compliant to the requirements of QS 9000 or not ????.
I only have an old copy of the APQP manual but things haven't changed in respect of goods receiving inspection. To quote from the Control Plan Methodology Overview, "In effect, the Control Plan describes the actions that are required at each phase of the process, including receiving, in-process, outgoing and periodic requirements to assure that all process outputs will be in a state of control."

Unless you include all stages of the process inspection, including goods receiving, in the Control Plan, you will not be compliant with the requirements of QS9000.
 
Thread starter Similar threads Forum Replies Date
K FMEA and Control Plan Header Content FMEA and Control Plans 6
E Content of Column 18 of the Control Plan FMEA and Control Plans 1
A Control Plan Content Requirements - GDP (Good Documentation Practices) APQP and PPAP 3
N Prototype Control Plan content - What has to be in a Prototype Control Plan? FMEA and Control Plans 2
D Process Control Plan Content: Relationship to PFMEA and Flow Diagram FMEA and Control Plans 3
Marc Control Plan content and fields - Format and Reaction Plan - 4.9.1 & 4.9.2 QS-9000 - American Automotive Manufacturers Standard 7
D Three Questions About Control Plan Content and Requirements FMEA and Control Plans 11
P IATF 16949 requirement - error-proofing in control plan IATF 16949 - Automotive Quality Systems Standard 2
earl62 What is the best way to control special characteristics in Control plan? Is it Mandatory to have SPC for IATF 16949? IATF 16949 - Automotive Quality Systems Standard 7
I Control Plan (Product/Process specification/ Tolerance) acceptance FMEA and Control Plans 27
J Control Plan use on the manufacturing floor FMEA and Control Plans 4
E Change in control plan - Do I have to do sampling? IATF 16949 - Automotive Quality Systems Standard 1
D All Dimensions listed on control plan FMEA and Control Plans 10
DuncanGibbons Manufacturing Plan vs Material Specification vs Control Plan Manufacturing and Related Processes 4
S Should safety checks be included in the Control Plan? IATF 16949 - Automotive Quality Systems Standard 5
D Supplied Product on Control Plan - Lot ranging in 40,000 pcs per product FMEA and Control Plans 3
M Is there any pre-defined Control plan format/template acc. VDA? VDA Standards - Germany's Automotive Standards 0
G Control Plan - Include the processes for each sub component? APQP and PPAP 2
A Redesigning our process flow chart, PFMEA and Control Plan Process Maps, Process Mapping and Turtle Diagrams 4
D Link between FMEA, flow chart and control plan FMEA and Control Plans 10
M Dynamic Control Plan Draft - need review FMEA and Control Plans 2
Ashland78 IATF 16949 Control Plan Authorizations IATF 16949 - Automotive Quality Systems Standard 2
N Control plan evaluation methods - Which methods should be carried over from the PFMEA? FMEA and Control Plans 3
Rameshwar25 What is a Control Plan at "Material Level"? IATF 16949 - Automotive Quality Systems Standard 4
L Control Plan - Multiple Process Steps FMEA and Control Plans 8
O Difference Between PFMEA & Control Plan FMEA and Control Plans 3
W Purchased Part Control Plan (IATF 16949) FMEA and Control Plans 7
J VDA audit, control plan - My hair is almost gone now VDA Standards - Germany's Automotive Standards 5
Howard Atkins MSAs are now required on every feature of the control plan - IATF 16949 IATF 16949 - Automotive Quality Systems Standard 13
Jeff Putman EQI Prelaunch Control Plan - Definition Customer and Company Specific Requirements 0
V How to Add Annual Revalidation requirements to Control Plan? FMEA and Control Plans 5
N Control plan references FMEA and Control Plans 6
L Simple Example for PFMEA / Control Plan Training Training - Internal, External, Online and Distance Learning 1
J Functional group / area responsible on a Control Plan IATF 16949 - Automotive Quality Systems Standard 1
T Should Testing be a separate operation in the Control Plan? FMEA and Control Plans 5
M Annual Layout requirements for PPAP/Control Plan FMEA and Control Plans 6
T IATF 16949 Control Plan and Process Monitoring Requirement(s) IATF 16949 - Automotive Quality Systems Standard 1
J Why Control Plan Review needs to be Approved by the Customer IATF 16949 - Automotive Quality Systems Standard 1
B PFMEA and Control Plan Links APQP and PPAP 2
A Corrective Action Column in Control Plan and aligning PFD, PFMEA and Control Plan FMEA and Control Plans 6
M Control Plan MSA's - Pressure Gages IATF 16949 - Automotive Quality Systems Standard 2
S Family / Generic type of FMEA & Control Plan and Symbols FMEA and Control Plans 3
V Do I need to add everything on print to control plan? FMEA and Control Plans 1
H Control plan example format for CNC machining activities FMEA and Control Plans 3
M Mention "according to Work Instruction" in Control Plan FMEA and Control Plans 3
W Does TS16949 require MSA on all measurement systems in the Control Plan? Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
T Software for linking Process Flow Diagram, Process FMEA and Control Plan APQP and PPAP 9
S Attribute G&R for all Visual Controls in Control Plan Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 1
I Any recommendations on software for managing the APQP, PPAP, PFMEA, Control Plan etc? Quality Assurance and Compliance Software Tools and Solutions 2
F What goes into a Control Plan? FMEA and Control Plans 1

Similar threads

Top Bottom