PRODUCT DEVELOPMENT

ORIGIN DATE PREP CHECK APPD

DOCUMENT NAME : DOCUMENT NO. CL/PD/05/00

REV. NO. 00
PROCEDURE OR GUIDELINES FOR PREPARING CONTROL
PLAN.
ISSUE DATE 14-04-10

PAGE NO. Page 1 of 4

1.0 PURPOSE :
This document provides the detailed Guidelines, explaining the method of preparing
control plan for all processes as covered in Scope given below.

2.0 SCOPE :
It is applicable to in-house manufacturing processes and covers all new products / processes and any
process change in existing products.

3.0 RESPONSIBILITY :
Although the over all responsibility for coordination of preparation and control of Control plan is with Product Development personnel
(assigned to the process/product), Control Plan input is
is thru a team consisting of various related deptt. Such as ProductDevelopment,Mfg.(Die casting
& m/cing), Quality assurance etc..

4.0 APPROVAL OF CONTROL PLAN :

The head of the Product Development function (Manager or above) will be authorised to approve the
Control Plan. All amendments / updation shall be approved by the same approving authority.

5.0 ASSUMPTIONS :
(a) The process Control Plan assumes the product as designed; will meet the design intent.
(b) It also assumes that the incoming parts / material are correct. (Specific exception can be made by
the Control Plan team where past historical data indicates deficiencies in incoming part quality).
( c) The Control Plan team members are knowledgeable individuals from their fields
( eg.Design,Process,Manufacturing,Quality etc.) and are adequately informed about the
manufacturing process and product requirements.

6.0 TIME OF PREPARATION AND REVIEW OF CONTROL PLAN

The Control Plan is a living document and is initiated :
a) At the process design stage after manufacturing process flow chart & PFMEA are completed.
b) Process Flow Chart shall account for all inhouse manufacturing processes including all sub
assemblies up to final inspection stage.

The Control Plan shall be reviewed and up dated under following conditions :
a) To be updated / amended, as and when any addition/change is made in manufacturing process due
to any quality problem or any other reason like change in Process parameters etc.
b) To be updated/amended , as and when any engg. Change incorporated in the part./in case of drg.
updation
c)To be updated/amended , as and when transfer from pre-launch to production control plan and change
in measurement frequency or change in Inspection method
d)To be updated/amended , as and when there is any change in sequence of process or addition of
process
 PRODUCT DEVELOPMENT

DOCUMENT NAME : DOCUMENT NO. CL/PD/05/00

REV. NO. 00
PROCEDURE OR GUIDELINES FOR PREPARING CONTROL
PLAN.
ISSUE DATE 14-04-10
PAGE NO. Page 2 of 4
7.0 CONTROL PLAN SEQUENCE

Process Machine, Device jig

Process No.
Name tools for manufacturing

Process name
Process no. as in Machine & jig used for
as in Process
Process flow that process.
flow.

Process Product
character stic charecterstic
Process character stic of Product charecterstic of
that process (Ex:- air that process.(Ex:-
pressure,temperature Dimns, Aesthetics Etc.)
Etc.)

Spel.Char.
class

Do any of process & product

Characterstic belongs to
special charecterstic(eg:-
critical,safety,function,mount
ing,special process.etc)

Spec.

What is the speccification of product/process charecterstic of that

process?

In-process,Bench,Sampling,special

Specification inspected either In-process,Bench,Sampling by which

method,whose responsibility at what frequency.

Reaction plan

If specification is not met in inspection what should be the reaction plan?

 PRODUCT DEVELOPMENT

DOCUMENT NAME : DOCUMENT NO. CL/PD/05/00

REV. NO. 00
PROCEDURE OR GUIDELINES FOR PREPARING CONTROL
PLAN.
ISSUE DATE 14-04-10
PAGE NO. Page 3 of 4
8.0 DEVELOPMENT OF CONTROL PLAN :

8.1 General
The responsible, PD personnel (DM/AM - Process or assigned process engineer) fills up all general data
related to CONTROL PLAN document number,revision no., product number,CFT Members name etc in
CONTROL PLAN format .

8.2 Process Function / Requirements :

The responsible PD personnel (as defined in 8.1) studies the process Flow Chart of the product and
enters a simple description of the process or operation being analysed ( eg melting,die casting,fettling
shotblasting,m/cing,painting,leakage testing,assembling etc).

8.3 Machine,Device,Jig Tools for Manufacturing :

Machine ,Jigs &Tools,gauges required to perform the concerned process are to be listed down.

8.4 Process charecterstics:-

All process charecterstics concerned to that process are to be listed down.(eg:- air pressure,
temperature,cutting speed,feed etc.)

8.5 Product charecterstics:-

All product charecterstics generated during that process are to be listed down.(eg:-dimensions,
surface finish,visual,etc.)

8.6 Special charecterstic class:-

Special charecterstic indicates the critical characterstic c , safety s

As per customer specification

8.7 Specification:-
Specification of both product & process charecterstics are to be listed down

8.8 In process inspection:-

This is the inspection carried out while processing in line . In this identify the method (gauge,instrument)
responsible person (Inspector,Engineer,Operator etc.) & sampling method(100% visual,1pc/4hrs,1/shift
1pc/2hrs,5pc/2hrs(5pc) decided as per customer requirement.
8.9 Bench inspection:-
This indicates the inspection carried out end of assy line separately at inspection bench

8.10. Sampling:-
This indicates the inspection carried out on sampling basis ( 1/day,1/month by Inspector or Engineer )
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DOCUMENT NAME : DOCUMENT NO. CL/PD/05/00

REV. NO. 00
PROCEDURE OR GUIDELINES FOR PREPARING CONTROL
PLAN.
ISSUE DATE 14-04-10

PAGE NO. Page 4 of 4

8.11 Reaction plan :
Reaction plan to be made for the process & product charecterstic specification is not met.

9.0 REFERENCES :
1) WI for codification of process Flow Chart
2) WI for pfmea study

10.0 RECORDS GENERATED.

Process flow chart.
PFMEA Format.
11.0 DISTRIBUTION

Document Holder Copy No.

Management Representative 01

Chief Manager Technology 02

General Manager QA 03

Chief Manufacturing Officer 04

12.0 AMENDMENTS

S.NO. Amendment Description Page No. Rev.No. Issue Date

1 Original Issue All 00 9/1/2006

This procedure is replaced by
2 previous guideline for control All 01 4/14/2007
plan building