Control Plan

Pre-Production Production
Company/Organization Name: Export Control Classification: Control Plan Number & Revision: Date (Original): Date (Revised):

Company/Organization Location: Other Restrictions: Customer Engineering Approval/Date (If Required):

Customer Quality Approval/Date (If Required):

Process Information
Part/Dwg Number: Program/Project: Other Approval/Date (If Required):

Part/Dwg Revision: Process Owner Name & E-mail: Other Approval/Date (If Required):

Part/Dwg or Family Name: Cross Functional Team Members:

Characteristics Methods
Sample

Classification
Machine, Product / Process Evaluation
Doc
Process Step Process Description Device, Jig, Reference Product Process Specification/ Measurement Size Frequency Control Method Reaction Plan
(Line) #
Tools For Mfg. Tolerance Technique

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© 2018 IAQG
The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)
 Template Issue Date 2019NOV26

Control Plan Revision History

Date Rev Revision Summary Approval

© 2019 IAQG  The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Am
h membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)
Example Control Plan
Pre-Production Production
Company/Organization Location: Enter the name of the company or organization who is responsible for the
Control Plan.

FairField Precision Machining

Company/Organization Location: Enter the location of the company or organization who is responsible for
the Control Plan.
Bridgend

Process Information

Part/Dwg Number: Enter the part or drawing number applicable to the Control Plan. If the Control Plan is for
a family, enter the representative part number.

KER55542921

Part/Dwg Revision: Enter the part or drawing revision of the Part/Dwg Number.

Rev 4

Part/Dwg or Family Name: Enter the part/drawing number name or the part family name.

Air Fuel Manifold Block

Characteristics

Machine,
Doc
Process Step Process Description Device, Jig, Reference Product
(Line) #
Tools For Mfg.
This List process identifier Provide an overview of what is Identify & enter all Provide a clear Capture a brief
column and a brief completed at each operation / the processing reference for description of product
should be description. step; equipment for each each product characteristics
updated Example: ..500 - ¨ What is expected to happen at process step. characteristic (outputs) aligned to
anytime Turning each operation / step? (e.g machine, listed - either a operation and
additional Ensure traceability ¨ State the description in clear, device, or other drawing location process step. These
rows are across Process Flow concise format, Use simple verb- tools for or section in a are product
added or Diagram, PFMEA and noun statements to describe manufacturing) manual or characteristics
deleted. Control Plan. functions as concisely as possible specification. It produced by process
Use for ¨ Identify all the functions should be the steps.
sorting e.g., Load billet onto machine tool same number as Ensure that the
purpose bed the process flow characteristic
only. e.g., Shot peen - blade tips diagram and attributes and
PFMEA. features are clear.
(e.g. Hole Diameter,
Part Length, Part
Width, Lap/Gap,...)

100.80 - Machine
Drill Holes in Fuel / Air Hermele CNC
1 Component - CNC X450 FN100 Fuel Hole Diameter
Drilling Manifold

Fixture Number
2 KER55542921-A-
05

Fuel Hole -
3 FN101 Through Hole
 Fuel Hole - No
4 FN 102 Burrs

6 FN103 Fuel Hole position

7 FN104 Air Hole Diameter

Air Hole - Through

8 FN105 Hole
 9 FN 106 Air Hole - No Burrs

10

11 FN107 Air Hole position

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© 2019 IAQG  The IAQG is a legally incorporated international not for profit association (INPA) with membership from th
 Control Plan Number & Revision: Enter a unique Control
Plan document number and revision used to help with
document control.
Export Control Classification: Enter the Export Control
Classification (if any).
None PCP-KER55542921-4
Other Restrictions: Enter any other applicable Customer Engineering Appro
restrictions (if any). approving the Control Plan a
None
Customer Quality Approval/D
the Control Plan and date of

Other Approval/Date (If Requ

Program/Project: Enter the program or project name.
and date of approval (if requ

Symmetry EP
Process Owner Name & E-mail: Enter the process owner responsible for the Control Plan Other Approval/Date (If Requ
including e-mail address. and date of approval (if requ

Thomas Alexander T.alexander@fairfieldPM.com

Cross Functional Team Members: Enter the names, functions, and e-mail address of each team
member involved with the development of the Control Plan.

L. Bennett, E. Capozzi, L. Pace, C. Catarina-Graca, I. Riggs

Characteristics Methods
Sample
Classification

Product / Process Evaluation

Process Specification/ Measurement Size Frequency
Tolerance Technique
Capture unique Enter a unique Enter the specification and Enter the measurement Enter sample Enter sample
process-related ID for special tolerances that come from system being used frequency and size frequency and size
characteristics that requirements various requirement (e.g. gages, tools, test (as required). (as required).
can affect the ability such as a Key documents (i.e. design equipment)
of the manufacturing Characteristic records, process
process to meet (KC), Critical specifications, processing
significant product Items (CI), or instructions).
characteristics. items requiring
Process additional
characteristics are design or
input to a given process
manufacturing controls.
operation. Ensure
(e.g Temperature, traceability
Pressure, Time, Drill across DFMEA,
Speed, Machine Process Flow
Global Accuracy Diagram,
Check,...) PFMEA and
Control Plan.

CMM Program at
KC-1 50mm +/- 0.2 mm 100%
OP500

Diameter check after

OP using diameter 100%
gauge G-DG-0025-A

Through Hole Visual check at OP600 100%

 No burrs. Refer to
KC-2 VS1012-FG-6 Visual check at OP600 100%

Coolant Strength 10 - 12% Refractometer Daily

X500, Y 750 +/- 0.1 mm CMM Program at

KC-3 (FN103) 100%
OP500

CMM Program at
30mm +/- 0.5 100%
OP500

Through Hole Visual check at OP600 100%

 No burrs. Refer to
VS1012-FG-6 Visual check at OP600 100%

Coolant Strength 10 - 12% Refractometer Daily

X500, Y 1250 +/- 1.0 mm CMM Program at

(FN107) 100%
OP500

ith membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)
 Template Issue Date 2019NOV26

Date (Original): Enter the original Date (Revised): Enter the new revision
Control Plan date. This is the date of date every time the Control Plan is
the first iteration of the Control Plan. updated.

9/5/2018 8/26/2019
omer Engineering Approval/Date (If Required): Enter the Customer Engineering name
oving the Control Plan and date of approval (if required).

omer Quality Approval/Date (If Required): Enter the Customer Quality name approving
Control Plan and date of approval (if required).

r Approval/Date (If Required): Enter the Other function / name approving the Control Plan
date of approval (if required).

r Approval/Date (If Required): Enter the Other function / name approving the Control Plan
date of approval (if required).

Control Method Reaction Plan

Enter methods used for detective and Provide a brief description that specifies actions
preventive control of each process step. The necessary and persons responsible to avoid
information is derived from the PFMEA. producing nonconforming product, process
Preventive controls (e.g. statistical process failure and/or operating out of control, and
control, error proofing) details containment plans to be invoked when
Detective controls (e.g. 100% inspection) nonconforming product is detected.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Inspection Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
I/MR SPC Chart Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Attribute SPC P-Chart Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.
 If part is found to be non-conforming
then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Attribute SPC P-Chart Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If coolant is found to be outside of

specification then stop production once
machine has finished its cycle amend
SPC I/MR Chart
inform manufacturing Engineering to
determine what actions are required to
rectify the situation.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Inspection Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Inspection Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Attribute SPC P-Chart Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.
 If part is found to be non-conforming
then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Attribute SPC P-Chart Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.

If coolant is found to be outside of

specification then stop production once
machine has finished its cycle amend
SPC I/MR Chart
inform manufacturing Engineering to
determine what actions are required to
rectify the situation.

If part is found to be non-conforming

then it is to be tagged with a non-
conformance label and placed into the
quarantine area for review.
Stop Production until Manufacturing
Inspection Engineering to review process and
determine what actions are taken to
prevent further non-conformance.
Any parts machined subsequently are
to be checked and sentenced
appropriately.
Control Plan Checklist (SCMH Section 7.2 www.iaqg.org/scmh - 7.2.7 APQP Phase 4

# Question Y* N N/A RYG

Was the Control Plan developed per customer requirements?
1
Have all the controls identified in the PFMEA been included
2 in the Control Plan?
Are all product/process Key Characteristics included in the
3 control plan?
Were DFMEA and PFMEA used to prepare the Control
4 Plan?
Are material specifications requiring inspection
5 identified?
Does the Control Plan address incoming
6 (material/components) through processing/assembly
including packaging?
Are engineering performance testing and dimensional
7 requirements identified?
Are gages and test equipment available as required by the
8 control plan?
Are the gage methodology and compatibility appropriate to
9 meet customer requirements?
Have measurement systems analysis been completed in
10 accordance with customer requirements?
Are sample sizes based upon industry standards, statistical
11 sampling plan tables, or other statistical process control
methods or techniques?
Have any additional risks including mitigation plans been
12 identified that may affect this deliverable?

X 25% N/A
IP 50%
25% - Action Identified 50% - Owner Identified
Status (%): 75% - Action in Progress 100% - Action Closed
75% R
100% Y
G

© 2019 IAQG  The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Am
7 APQP Phase 4 Checklist 26OCT2018)

Evidence Actions R

Deliverable RYG Rating

Red: Some questions have a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is required. When an item is highlighted
Red an Some
Yellow: assessment on the
questions impact
have to the WP
a negative timing
answer butneeds to be plan
a recovery provided.
is in place which will
prevent impact on timing
Green: All questions have a positive answer (Y) and are ongoing normal program development

membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)
 Template Issue Date 2019NOV26

Open Due Status

Actions Required Responsible Date Date %

Location: / Site:

Reviewed by:
Reviewed with:
Date :
te Issue Date 2019NOV26

Actual End
Date