Operator understanding of what Control Plans are and how they are used

C

CMfgT

#1
Right now our inspection sheets are on the shop floor and our control plans are just quality documents we keep internally…and if an auditor asked our operators if they use the control plan, they would say “what is a control plan”. I am new to this position, but I know the control plan should be a living document with our inspection sheets and the operators should have a control plan so they know what to do if a problem arises. What do you guys/gals do at your facility? Do you have control plans in the factory? If so how do you use/manage them for operator use?
Does anyone have control plans and inspection sheets combined on one document? I guess I am looking for suggestions or examples on how to implement this. In a perfect world, as you edit an inspection sheet in a data base such as excel, the control plan will update on another sheet or same sheet. Just don’t know how feasible this is.

Thanks,
 
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harrysons

Realistic Quality
#2
Re: Control Plans & Inspection Sheets

My experiences The Control plan between inspection sheet separated. we kept the control plan at the distribution department, the operator won't keep the control plan such as inspection sheet, we used the control plan to identified each process step till inspection.
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#3
Re: Control Plans & Inspection Sheets

The control plan is the master plan for controls throughout the production cycles, including inspection. The control plan is used by engineering and management to develop routers, special instructions and yes, inspection plans, but operators and inspectors are not typically shown these master documents so they usually don't know what they are.
 

Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#4
Re: Control Plans & Inspection Sheets

My experiences The Control plan between inspection sheet separated. we kept the control plan at the distribution department, the operator won't keep the control plan such as inspection sheet, we used the control plan to identified each process step till inspection.
Welcome to the Cove! :bigwave: Thank you for sharing your experience. I look forward to seeing you around!
 

Jim Wynne

Staff member
Admin
#5
Re: Control Plans & Inspection Sheets

Right now our inspection sheets are on the shop floor and our control plans are just quality documents we keep internally…and if an auditor asked our operators if they use the control plan, they would say “what is a control plan”. I am new to this position, but I know the control plan should be a living document with our inspection sheets and the operators should have a control plan so they know what to do if a problem arises. What do you guys/gals do at your facility? Do you have control plans in the factory? If so how do you use/manage them for operator use?
Does anyone have control plans and inspection sheets combined on one document? I guess I am looking for suggestions or examples on how to implement this. In a perfect world, as you edit an inspection sheet in a data base such as excel, the control plan will update on another sheet or same sheet. Just don’t know how feasible this is.

Thanks,
On the assumption that you're referring to the AIAG control plan, the format isn't particularly user-friendly and they're often used (a) to satisfy customer requirements and/or (b) as so-called "master" documents that form the basis for shop-floor documentation.

So long as there is a current control plan and the shop documents don't contradict it, there's no auditor should have an issue with there being no copies in the shop, or operator awareness of it. Note that I'm not saying that it's a good idea for operators to be ignorant of the existence of a control plan.
 
C

CMfgT

#6
Re: Control Plans & Inspection Sheets

Thanks for all of the replies.

I guess Jim Wynne, you hit the nail on the head. I don't want the operators to be ignorant of the control plans. I want them to now what action to take when a problem arises. I need to find a balance between inspection sheet and control plans...and most of all a way to manage them.
 

Jim Wynne

Staff member
Admin
#7
Re: Control Plans & Inspection Sheets

Thanks for all of the replies.

I guess Jim Wynne, you hit the nail on the head. I don't want the operators to be ignorant of the control plans. I want them to now what action to take when a problem arises. I need to find a balance between inspection sheet and control plans...and most of all a way to manage them.
There are ways other than a control plan to make people aware of the requirements. You can integrate the "reaction plan" into the shop floor documentation, or you can provide supplemental training and instructions. For example, you should already have a procedure for handling nonconforming material, and your operators should be aware of it.

In any case, if you feel that a copy of the control plan itself is the best way to go, then that's what you should do.
 

C.R.V.G.

Quality Engineer
#8
Hello!

Long time no posting on this forum... but, I would like to raise another question related to this issue: has anyone here any systematic of keeping only one document covering all information from "AIAG control plan" and "shop floor process sheet" in place?

I mean, it would be easier to manage the updates if we work with only one source of information, right? Otherwise some information could be missed or mismatched from one document to another in an updating situation.

I appreciate any feedback on this point!


Regards,
- Bruno
 
Last edited:

Ron Rompen

Trusted Information Resource
#9
Hello!

Long time no posting on this forum... but, I would like to raise another question related to this issue: has anyone here any systematic of keeping only one document covering all information from "AIAG control plan" and "shop floor process sheet" in place?

I mean, it would be easier to manage the updates if we work with only one source of information, right? Otherwise some information could be missed or mismatched from one document to another in an updating situation.

I appreciate any feedback on this point!


Regards,
- Bruno
There is (as far as I know) available a disk or CD which contains all the recommended AIAG documents (PFMEA, Control Plan, APQP documents, Dimensional Report, PPAP warrant, etc etc) which are contained in a linked Excel spreadsheet. Cant recall who published/sold it, but I am sure there is someone here who still has access to it, and can provide that information.

The only document I recall as being missing from the package was the in-process inspection sheet - this is something that you would add, and create the links within the document, and then have a complete package. If you create the links properly, then when you update one document, you update ALL of the documents at the same time.
 
#10
Control Plans on the floor has been a debate at most places I worked since 1992 and still it rages on. I actually have a question about Control Plans on the shop floor as well. I had a customer audit me using what he said was some version of a VDA audit though when I looked through it I think it was more of a Frankenstein audit where he pulled select questions from of a few different audits that I have seen over the years. Anyway though I personally prefer NOT to have CP's on the floor because it is a controlled document latest revision non-conformance just waiting to happen, we have them in the job books. When the customer audited the job book he saw the CP and quickly asked the operator if he knew what it was and if he understood or was ever trained on the document. Of course the Op said no and we were written up for it because the customer said that all documents in the Job Book need to be clearly understood by the operator. My question is this a real requirement or his requirement? He is the customer and he is requiring it so I guess it makes it kind of a customer requirement but is this a requirement listed in any of the recognized standards?
 
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