CPQP

TOOLSET
GUIDELINE 8

Control Plan Guideline

Version 1.0

August 2022
Contents

Use of this Guide 4

Introduction 5
Background 6
Purpose 6
Benefits 7
How does Control Plan fit in with Construction Product Quality Planning? 8
Team Approach 8

Methodology 9

Guideline 12
Step 1: Assign Control Plan Team 13
Step 2: Collect Outputs from PFMEA 13
Step 3: Prioritise Process Risk 13
Step 4: Population of Control Plan 13
Step 5: Control Plan Action 14
Step 6: Reaction Plan 14
Step 7: Process Validation 14
Step 8: Handover 14

Worked Example 15
Step 1: Assign Control Plan Team 16
Step 2: Collect Outputs from PFMEA 17
Step 3: Prioritise Process Risk 20
Step 4: Population of Control Plan 21
Step 5: Control Plan Action 22
Step 6: Reaction Plan 23
Step 7 & 8: Process Validation & Handover 23

References and Appendices 25

References 26
Appendix A. Tool Templates 27
Appendix B. List of Abbreviations 30
Appendix C. Glossary of Terms 30

Construction Product Quality Planning (CPQP) Control Plan Guideline 2

List of figures

Figure 1. Construction Product Quality Planning (CPQP) Process 8

Figure 2. Prevention and Detection Control Documentation 10
Figure 3: Control Plan Inputs 11
Figure 4. Control Plan Team Selection 16
Figure 5. Control Plan Heading Section 17
Figure 6. Control Plan Number 17
Figure 7. Control Plan Project Description & Summary 18
Figure 8. Control Plan Primary Parties 18
Figure 9. Control Plan Part Description 19
Figure 10. Control Plan and PFMEA Link Information 19
Figure 11. Control Plan Revision Control 20
Figure 12. Control Plan Failure Mode Population 20
Figure 13. Control Plan Process Description 21
Figure 14. Control Plan Key Classification 21
Figure 15. Control Plan Potential Failure Modes 21
Figure 16. Control Plan Tools / Machine Used & Control Method 22
Figure 17. Control Plan Evaluation & Reaction Plan 23

List of tables

Table 1. Control Plan Template, 2D Prefabricated Panel Installation 24

Table 2: Control Plan Template 28
Table 3: PFMEA Template 29

Construction Product Quality Planning (CPQP) Control Plan Guideline 3

Use of this Guide

enough knowledge to enable the CPQP team

to complete a Control Plan, particularly where
The Control Plan guideline is part of the
this subject is new to them, as well as to provide
Construction Product Quality Planning
ongoing aid. Over time, companies will develop
(CPQP) process and should be used in their own expertise, methods and standards
conjunction with the CPQP Guide and its through training and practice.
toolset, published by the Construction
For a list of the acronyms and abbreviations used
Innovation Hub.
in this document, refer to Appendix B – List

Intended as a guideline to aid the process of of Abbreviations.

creating Control Plans, this document provides the

For the various terms used in this document, refer
basic principles and a suggested methodology.
to Appendix C – Glossary of Terms.
The templates provided can be changed and
modified to suit individual companies.

This guideline is intended for use by companies For further information about the CPQP Guide
manufacturing offsite construction products and its toolset please contact:
largely using the CPQP process with their cpqp@constructioninnovationhub.org.uk
customers and suppliers. It aims to provide

Construction Product Quality Planning (CPQP) Control Plan Guideline 4

Introduction

Construction Product Quality Planning (CPQP) Control Plan Guideline 5

Introduction

The adoption of these risk control measures in the

Control Plans provide a structured automotive, aerospace, and other manufacturing

industries has delivered significant improvement with
approach to define control actions
regards to defect prevention, quality control, and
required at each process step to ensure cost reduction. Companies that use Control Plans
process outputs meet the pre-determined realise that monitoring and controlling the high-risk
requirements. Control Plans provide the items identified in the Process Failure Mode and

production team with a description of Effects Analysis (PFMEA) enable the team to evaluate
process or product for strengths and weaknesses
the process control mechanisms (e.g.
and to prevent problems before they occur.
measurements, inspections, quality Highlighting these risks and formulating control
checks and monitoring of product and mechanisms for these processes is imperative before
process parameters) to assure that tooling and finalising the manufacturing process, as
quality requirements and standards are the costs of revisions at a later stage are significant.

met throughout the production process

Purpose
and the risk of producing defective or
non-conforming products are The main purpose of using Control Plans is to
mitigated. monitor and control process quality by providing
actionable control methods to reduce the risks
The tool (usually presented as a spreadsheet highlighted in the PFMEA. This assures that any
template) addresses key risks identified in process improvements are also maintained over
the Process Failure Modes, Effects & Analysis the lifecycle of the part.
(PFMEA), another tool used by engineers to
identify potential failures that could occur in a The Control Plan is a key element of a structured
manufacturing process and for which a guideline process and contributes to effectively foster a
is also available as part of the CPQP toolset; culture of defect prevention. The Control Plan, along
Process Failure Modes and Effect Analysis with the PFMEA, reduce defects propagating through
(PFMEA). manufacture, assembly, and construction phases
and effectively error-proof the project. Therefore,
Besides defining control methods, the Control Plan using the Control Plan acts as an enabler in shifting
also provides the operator with a reaction plan the focus of the team from quality control and
that sets out actions for the operator when non- defect checking to quality assurance and defect
conformance is detected. prevention. The Control Plan ensures ongoing
monitoring is carried out by controlling
Background the key sources of variation in the process, which
in turn leads to a predictable process and a defect-
Control Plans are well established in other
free product.
industries, such as aerospace, automotive, heavy
equipment and many other industries, to ensure
product quality standards are met by minimising
product and process variation [1].

Construction Product Quality Planning (CPQP) Control Plan Guideline 6

Benefits

The Control Plan benefits have been documented • Increased customer satisfaction:
in various industries. The expenditure within Key product and process instructions, actions,
businesses is ever increasing with the rising and control methods documented in the Control
costs of raw material and labour and the need Plan contribute to delivering a product with a
for advanced equipment. The majority of high level of customer perceived quality;
manufacturing companies today are looking for
ways to reduce cost by eliminating waste within • Effective communication:

processes, while ensuring that the parts produced Successful implementation of a control

conform to customer requirements every time. method for a process risk requires ongoing
communication This level of involvement to
Some of the benefits associated with the Control deliver a solution improves communication
Plan include: within the relevant team, across the organisation
and, importantly, with the team on the shop
• Process defect prevention: floor. The documented control methods and
Actionable tasks make it possible to monitor, actions should provide operators with clear
control, and remove or reduce variation within instructions to ensure processes and products
a process. This contributes to the overall process meet the pre-defined requirements; and
efficiency and eventually to the reduction in the
number of non-conforming parts; • Team Engagement:
A cross-functional team develops and manages
• Efficient use of resources: the Control Plan to ensure that the high-risk
Clear and actionable process control methods features or characteristics identified in the
contribute to improving product quality, PFMEA are either mitigated or prevented.
reducing waste, and eliminating costly rework;

• Cost savings:
Proactive plans to mitigate issues early within
production processes contribute to significant
savings relative to implementing a solution once
production is already underway;

Construction Product Quality Planning (CPQP) Control Plan Guideline 7

How does the Control Plan fit in Plan are paired together within the CPQP process
to enable the delivery of products to ensure
with Construction Product Quality customer satisfaction.
Planning?
Team Approach
The Construction Product Quality Planning (CPQP)
process supports the development of new products The advanced planning approach in the CPQP
for manufacturing-led construction approaches. is built upon a team-based approach. Similarly,
The process covers the entire product development the effective use of the Control Plan tool requires
cycle, from concept design through to product the engagement and participation of a cross-
launch. The Construction Product Quality Planning functional team. The team composition will vary
(CPQP) process has been broken down into by organisation and the needs of the process
five phases as shown in Figure 1. Similar to the improvement. However, the team should include
Process Failure Mode and Effect Analysis (PFMEA) members from a variety of disciplines with
document, the Control Plan is developed during relevant knowledge and experience (i.e. design,
phase 3 (Process Design & Development) of the process, manufacturing and quality departments)
CPQP process. Therefore, the PFMEA and Control to ensure that the Control Plan is actionable and
facilitates the work of the team on the shop floor.

Project Established Design Process Manufacturing Production Part

Initiation Supply Chain Approval Approval Approval Sign-Off

CPQP
Milestones

Product Launch
P1 Planning P5
& Ongoing Monitoring

CPQP Product Design

P2 P4 Produc t & Process Validation
Phases & Development

P3 Process Design & De velopment

CPQP
Approval G1 G2 G3 G4 G5
Process
Production Readiness Review

Figure 1. Construction Product Quality Planning (CPQP) Process

Construction Product Quality Planning (CPQP) Control Plan Guideline 8

Methodology

Construction Product Quality Planning (CPQP) Control Plan Guideline 9

Methodology

for these key characteristics of the process to

deliver the product.
The Control Plan details the controls
required at each step of the production and In general, Control Plans provide details of the in-
assembly processes. It includes checking process checks that need to be completed during
product characteristics (e.g. dimensions, the manufacturing of a specific product. Some
other controls are specific to the general process
surface finishes, evidence of damages)
rather than to specific product manufacturing
as well as process characteristics (e.g.
processes. This is the case for instance of
pressures, temperatures, step duration). maintenance and equipment inspections which
are then covered in the maintenance plan.
The results of the PFMEA usually feed into the Control
Plan. It is during the PFMEA that the team identifies Figure 2 illustrates how the Control Plan fits in
the high-risk items and key process characteristics the documentation breakdown structure for the
that need to be monitored and controlled. The outputs of the PFMEA. For information on PFMEA
PFMEA also identifies the prevention and detection and a copy of the template, refer to the Process
controls that need to be in place to mitigate the Failure Modes and Effect Analysis (PFMEA)
identified risk. Mitigation of these risks forms part of guideline, which forms part of the CPQP toolsets.
the Control Plan, which details the control method

PFMEA
Identified detection controls must be
categorised within the following method

Control Plan Maintenance Plan Inspection Plan

Figure 2. Prevention and Detection Control Documentation

Construction Product Quality Planning (CPQP) Control Plan Guideline 10

The development of the Control Plan requires a design intent for the product is protected from
cross-functional team with the expertise to define end to end and that the process parameters are
the process control mechanisms that can prevent monitored to ensure consistent product quality [2].
the root causes for failures. The control method Figure 3 illustrates the key inputs used to develop
selected within the Control Plan ensures that the the Control Plan.

Process Flow Diagram

Key Characteristics List

Process FMEA
Control
MSA
Lessons Learned from Plan
Similar Parts

MSA

Team Knowledge

Figure 3: Control Plan Inputs

It is important to ensure that the Control Plan • Accessibility: The correct Control Plan should
is updated at regular intervals and reflects be easy to locate and identify. The document
the current manufacturing process. needs to be easily accessible by the team in the
shop floor so they can refer to it to carry out
Along with the process control mechanisms, the required check when during the process;
the Control Plan specifies a separate reaction
plan for each high-risk item. The reaction plan • Document size: The Control Plan should
comes into use in the event of a failure of the present the information clearly and concisely.
control method itself, for example, instances Overcrowded plans can make it difficult for
where an error-proofing fixture might break. operators to quickly identify actions required
for control measures; and
The effectiveness of the actions and controls
described in the Control Plans depends on its • Updated document: Control Plans are linked to
deployment and the adoption on the shop the PFMEA. Updates to the PFMEA need to be
floor. Some of the more common issues that translated into the Control Plan. Both the PFMEA
teams can face during the implementation of and the Control Plan are live documents; they
the Control Plan are: need to be updated regularly following any
changes in the processes.

Construction Product Quality Planning (CPQP) Control Plan Guideline 11

Guideline

Construction Product Quality Planning (CPQP) Control Plan Guideline 12

Guideline

The following steps describe the process to create Step 4: Population of Control Plan
a Control Plan. These steps provide high-level
information on the requirements. Detailed steps are Begin populating the document based on the
provided in the Worked Example section. PFMEA template. Essential data required for the
Control Plan includes:
Step 1: Assign Control Plan Team
• Description of failure mode;
Assign a cross-functional team to carry out the
• Feature or Part Number;
actions agreed upon in the PFMEA.

• Part description;
Step 2: Collect Outputs from PFMEA
• Component features;
Capture the outputs from the PFMEA and other
sources, making sure that all aspects shown in • Summary of operation;
Figure 2 have been considered.
• Risk Classification;

Step 3: Prioritise Process Risk • Failure Modes;

Prioritise failure modes based on the highest process • Measurement methods; and
risk to lowest for each operation. If a failure mode
in the PFMEA is common and has been mentioned • Control Methods.
for several other operations, then due diligence is
required to confirm if repetition can be avoided.

Construction Product Quality Planning (CPQP) Control Plan Guideline 13

Step 5: Control Plan Action Step 7: Process Validation
The required control method will be carried out Process validation should be signed-off on by the
for each stage by the relevant operator. The quality manager after ensuring that the Control
actions should be described in the Control Plan. Plan has been completed with no outstanding
issues and all actions have been closed.
Step 6: Reaction Plan
Step 8: Handover
If a planned control method fails, the Control
Plan also provides the operator with a reaction Hand over each process template to the relevant
plan, for example, machine stoppage. A good operators, who are responsible for completing
practice on a manufacturing shop floor is to have the template and have full working knowledge
some key reaction plans in the form of laminated of the operation, product characteristics, and
numbered documents (e.g. reaction plan 1, product/process specifications. These actions
reaction plan 2 and so on), which can be quickly should ensure that risks are mitigated and
implemented during uncertain situations. prevented wherever possible. Only in instances
where it may not be possible to mitigate certain
risks, the team should ensure that high-fidelity
detection mechanisms are put in place.

Construction Product Quality Planning (CPQP) Control Plan Guideline 14

Worked Example

Construction Product Quality Planning (CPQP) Control Plan Guideline 15

Worked example

joined before being shipped to the site for building

assembly. The Control Plan is a continuation of the
Based on the methodology discussed in
PFMEA worked example from the PFMEA Guideline
the previous section, the implementation
released from the Construction Innovation Hub. The
of the Control Plan is outlined using a failure modes with the highest Risk Priority Number
worked example. This step-by-step worked (RPN) are taken forward to the Control Plan. This
example should lead to a fully populated worked example considers the two highest risk

Control Plan. This can be found at the end items: loading the panel face down and loading a
panel with the wrong colour, with RPNs of 70 and 56,
of this section in Table 1. The example
respectively.
should not be regarded as a complete
and comprehensive case study; it aims Step 1: Assign Control Plan Team
only to illustrate the implementation of
The initial step is to select a team to carry out the
the Control Plan in a simple manner.
actions agreed upon in the PFMEA. This can be the
The worked example considers the off-site same team that completed the PFMEA, or another
manufacturing of an insulated wall system. The wall team determined internally. Details of the selected
system comprises a sandwich structure composed team are recorded in the template (Figure 4).
of a gypsum fibreboard and an insulation board

Name Position Email

Luke Harrington Manufacturing Engineer L.Harrington@example.co.uk

Amelie Hamilton Design Engineer A.Hamilton@example.co.uk

Lauren Cannon Quality Engineer L.Cannon@example.co.uk

Dylan Reese Production Manager D.Reese@example.co.uk

Alyssa Finley Manufacturing Team Leader A.Finley@example.co.uk

Figure 4. Control Plan Team Selection

Construction Product Quality Planning (CPQP) Control Plan Guideline 16

Step 2: Collect Outputs from PFMEA

All relevant information needs to be added in section (Figure 5). This includes details of
the template to allow quick and easy referencing operations, actions and parts within the plan.
of the operations in the Control Plan heading

Control Plan

Processes/
Location Operations
Manufacturer Fireboard Covered
PFMEA PFMEA
Project Future Cell Wall System (FMEA Solutions
Number FC.20
Owner) Limited Insulated Wall
Watford Factory Panel Sub
Assembly

Offsite manufacture of new Process

wall system for Prisons. Wall Location Flow Chart
sections will comprise of an ABC Main References 03-Nov-
Customer Date
Insulated Wall Panel and an Contractor 20
Project
Uninsulated wall panel of
Description Birmingham (site)
standard sizes. Complete Op20 - Insulated
the wall system before Wall Panel Sub
shipping to site for building Assembly
Team Revision B
assembly.

Part Name Part Number Rev Name Position Email Summary: Revision notes:

This process flow Updated after PFMEA

Insulated Luke Manufacturing
FSL213 2 L.Harrington@example.co.uk covers the sub RPN reduction actions
Wall Panel Harrington Engineer
assembly of the were implemented.
Insulated Wall
Amelie Design Panel ready for
A.Hamilton@example.co.uk
Hamilton Engineer assembly with the
uninsulated Wall
Lauren Quality Panel to complete
L.Cannon@example.co.uk
Cannon Engineer the Wall System.
Made on Panel
Sub Assembly
Production
Dylan Reese D.Reese@example.co.uk Line 1.
Manager

Manufacturing
Alyssa Finley A.Finley@example.co.uk
Team Leader

Figure 5. Control Plan Heading Section

The Control Plan Number (CP Number) for Plan Number is CP FC.20 and the PFMEA Number
the document is added. This is related to the is PFMEA FC.20. The CP number is found in
PFMEA Number. In this example, the Control the top-right-hand corner (Figure 6).

Control Plan Number CP FC. 20

Figure 6. Control Plan Number

Construction Product Quality Planning (CPQP) Control Plan Guideline 17

The project name, description, and summary are cells show what the aim of this process is and
populated based on the PFMEA template (Figure provide guidance on what the plan is trying to
7). This can be copied from the PFMEA document achieve. In this example, the aim is to manufacture
if needed. The overall project is the final product a new system of prison walls comprised of
that is compiled of the sub-parts. These populated insulated and uninsulated wall panels.

Project Future Cell Wall System

Offsite manufacture of new

wall system for Prisons. Wall
Summary:
sections will comprise of an
Insulated Wall Panel and an
This process flow covers the sub assembly of the Insulated
Project Description Uninsulated wall panel of
Wall Panel ready for assembly with the uninsulated Wall
standard sizes. Complete
Panel to complete the Wall System. Made on Panel Sub
the wall system before
Assembly Line 1.
shipping to site for building
assembly.

Figure 7. Control Plan Project Description & Summary

A record of the two primary parties involved is

populated (Figure 8). The manufacturer and the
customer information, including their location,
is populated.

Location
Manufacturer (FMEA
Fireboard Solutions Limited
Owner)
Watford Factory

Location
Customer ABC Main Contractor
Birmingham (site)

Figure 8. Control Plan Primary Parties

Construction Product Quality Planning (CPQP) Control Plan Guideline 18

Parts and sub-parts assembled within this process the differing risks that are applicable to different
flow are recorded (Figure 9). The part name, designs or materials. This example considers the
number, and revision/iteration are the key inputs insulated wall panel process risk.
required. The revision/iteration is important due to

Part Name Part Number Rev

Insulated Wall Panel FSL213 2

Figure 9. Control Plan Part Description

A link to the PFMEA document number is recorded reference are also entered. This data is important
on the Control Plan. Alongside this information, the with regards to providing a link between the PFMEA
process/operation covered and process flow chart and Control Plan (Figure 10).

Processes/Operations Covered
PFMEA
Number PFMEA FC.20
Insulated Wall Panel

Process Flow Chart References Date 03-Nov-20

Op20 - Insulated Wall Panel Sub Assembly Revision B

Figure 10. Control Plan and PFMEA Link Information

Construction Product Quality Planning (CPQP) Control Plan Guideline 19

A record of updates to the Control Plan is
documented (Figure 11). It is imperative to include
revision, date of revision and the description of the
details of the last revision to ensure the end user
can track changes.

Date 03-Nov-20

Revision B

Revision notes:

Updated after PFMEA RPN reduction actions were implemented.

Figure 11. Control Plan Revision Control

Step 3: Prioritise Based on

RPN Score
This section of the Control Plan is based on the on RPN from highest to lowest for each operation.
PFMEA failure modes (Figure 12). The order is based Each section is further detailed below.

Process/ Process/
Process Key Tool/Machine Evaluation
Op Opperation Failure Mode Control Method Tolerance Reaction Plan
Revision Characteristic Used Technique
Number Description

Remove
Use sensor to
Colour scanner Gypsum
detect if 'light'
will identify Fibreboard
internal or
the part, which Panel from
Panel loaded 'darker' external
the system will conveyer
CC face down on Colour Sensor side is facing N/A
Place large determine if it is belt. Return
conveyor up. Machine will
external Gypsum the correct part to starting
no cycle until
Fibreboard panel or not. Staff will position, with
orientation is
(base part no. act on results. panel loaded
detected.
234768) of the face down.
20.1 B
right external
colour finish Scan barcode
onto roller bed Bar code scanner
of panel into Remove
in the correct will identify
Wrong colour the system so Gypsum
orientation the part, which
panel loaded machine knows Fibreboard
Bar Code the system will
SC - different correct part N/A Panel from
Scanner determine if it is
external finish loaded and cycle conveyer belt.
the correct part
spec will not start until Notify line
or not. Staff will
correct board manager.
act on results.
present.

Figure 12. Control Plan Failure Mode Population

Construction Product Quality Planning (CPQP) Control Plan Guideline 20

Step 4: Population of the 13). In this example, the PFMEA highlights that

Control Plan the highest risk is the potential of the wrong

component being used, which can lead to two
The first three columns are populated with the potential failures. These failures are recorded
Process/Operation number, its description, and on the lower section of the Control Plan
the revision of the operation to keep track of the highlighting the operational description. This
number of times the controls have been changed description gives a more detailed account of
due to quality escapes or other problems (Figure how to successfully accomplish this process.

Process/ Process/ Process

Key Characteristic
Op Number Opperation Description Revision

Place large external Gypsum Fibreboard panel (base part no. CC

20.1 234768) of the right external colour finish onto roller bed in the B
correct orientation
SC

Figure 13. Control Plan Process Description

The characteristic level of the operation is taken The Failure Modes are obtained from the PFMEA. The
from the corresponding PFMEA (Figure 14). This two highest RPN scored failure modes are shown in
can be classed as either a Critical (CC), Significant Figure 15. In this instance, two possible failure modes
(SC), or Unclassified Characteristic (UC). relate to the assembly process: the orientation of
the board required to build the wall panel and the
wrong panel colour loaded.

Key Characteristic Failure Mode

Panel loaded face down on conveyor

CC

Wrong colour panel loaded - different external finish spec

SC

Figure 14. Control Plan Key Classification Figure 15. Control Plan Potential Failure Modes

Construction Product Quality Planning (CPQP) Control Plan Guideline 21

Step 5: Control Plan Action

The next two columns are populated with conveyer. In both instances, the control states
information highlighting the control method and the conveyer belt will not cycle forward to the
the associated tools (Figure 16). In this instance, workstation until the correct board is present and
the use of a sensor or scanner allows the control facing the correct side.
method to be adhered to. The two control methods
use a sensor to detect which side of the gypsum The next step is to populate the tolerance of the

fibreboard panel is on the conveyor using a light failure mode characteristic. This column is used to

sensor and scanning the barcode of the panel state a customer requirement.

to ensure the correct panel is loaded onto the

Tool/Machine Used Control Method

Use sensor to detect if 'light' internal or 'darker' external side is

Colour Sensor
facing up. Machine will no cycle until orientation is detected.

Scan barcode of panel into the system so machine knows

Bar Code Scanner correct part loaded and cycle will not start until correct board
present.

Figure 16. Control Plan Tools / Machine Used & Control Method

Construction Product Quality Planning (CPQP) Control Plan Guideline 22

Step 6: Reaction Plan

The final two columns of this example deal with the and its orientation. At this point, the operator has
technique to control the process and creation of a a control method and how to execute it – which
reaction plan (Figure 17). The evaluation technique is removes both process risks. Finally, the reaction
pivotal in providing greater detail on how to execute plan informs the operator of the necessary steps to
the control method. To ensure the panel is facing the take in the event of an unexpected failure. In this
correct side and the correct panel is loaded, the two instance, a staff member must manually remove
scanners are integrated as part of an automated the panel from the line and either place it in its
detection system. Both techniques ensure that the correct orientation at the starting point or inform a
staff play no role in determining the correct panel manager that the incorrect part has been loaded.

Evaluation Technique Reaction Plan

Colour scanner will identify the part, which the system will
Remove Gypsum Fibreboard Panel from conveyer belt. Return to
determine if it is the correct part or not. Staff will act on
starting position, with panel loaded face down.
results.

Bar code scanner will identify the part, which the system
Remove Gypsum Fibreboard Panel from conveyer belt. Notify
will determine if it is the correct part or not. Staff will act on
line manager.
results.

Figure 17. Control Plan Evaluation & Reaction Plan

Step 7 & 8: Process Validation

& Handover

Process validation is signed-off on by the quality The team then hands over each process’s template
manager, who ensures that the Control Plan is to the relevant operators who are responsible for
complete with no outstanding issues and all the completing the template and have full working
actions are closed. knowledge of the operation, product characteristics,
and product/process specifications. These actions
ensure that the risks are mitigated and prevented
wherever possible.

Construction Product Quality Planning (CPQP) Control Plan Guideline 23

 Control Plan Control Plan Number CP FC. 20

Processes/Operations
Location
Covered
Manufacturer PFMEA PFMEA
Project Future Cell Wall System Fireboard Solutions Limited Page 1 of 1
(FMEA Owner) Number FC.20
Insulated Wall Panel Sub
Watford Factory
Assembly

Offsite manufacture of new wall Process Flow Chart

Location
References 03-
system for Prisons. Wall sections
Customer ABC Main Contractor Date Nov-
will comprise of an Insulated Wall
20
Project Description Panel and an Uninsulated wall Birmingham (site)
panel of standard sizes. Complete Op20 - Insulated Wall
the wall system before shipping to Panel Sub Assembly
site for building assembly. Team Revision B

Part Name Part Number Rev Name Position Email Summary: Revision notes:

This process flow covers Updated after PFMEA

Insulated Wall Panel FSL213 2 Luke Harrington Manufacturing Engineer L.Harrington@example.co.uk
the sub assembly of the RPN reduction actions
Insulated Wall Panel ready were implemented.
Amelie Hamilton Design Engineer A.Hamilton@example.co.uk for assembly with the
uninsulated Wall Panel to
complete the Wall System.
Lauren Cannon Quality Engineer L.Cannon@example.co.uk Made on Panel Sub
Assembly Line 1.

Dylan Reese Production Manager D.Reese@example.co.uk

Alyssa Finley Manufacturing Team Leader A.Finley@example.co.uk

Process/
Process/ Process Key
Op Failure Mode Tool/Machine Used Control Method Tolerance Evaluation Technique Reaction Plan
Opperation Description Revision Characteristic
Number

Remove Gypsum
Use sensor to detect if Colour scanner will identify
Fibreboard Panel
Panel loaded 'light' internal or 'darker' the part, which the system will
from conveyer belt.
CC face down on Colour Sensor external side is facing up. N/A determine if it is the correct
Return to starting
conveyor Machine will no cycle until part or not. Staff will act on
Place large external Gypsum position, with panel
orientation is detected. results.
Fibreboard panel (base part no. loaded face down.
20.1 234768) of the right external colour B
finish onto roller bed in the correct Scan barcode of panel
orientation Bar code scanner will identify
Wrong colour into the system so Remove Gypsum
the part, which the system will
panel loaded - machine knows correct Fibreboard Panel
SC Bar Code Scanner N/A determine if it is the correct
different external part loaded and cycle from conveyer belt.
part or not. Staff will act on
finish spec will not start until correct Notify line manager.
results.
board present.

Table 1. Control Plan Template, 2D Prefabricated Panel Installation

Construction Product Quality Planning (CPQP) Control Plan Guideline 24

References and Appendices

Construction Product Quality Planning (CPQP) Control Plan Guideline 25

References

[1] Quality One International. Quality-One International. Retrieved

December 2nd, 2020, from https://quality-one.com/control-plan/

[2] British Standards Institution. (2011). Aerospace series. Paints and varnishes.
Test method for determination of chromate leaching. BS EN 4195. Retrieved
from: https://shop.bsigroup.com/ProductDetail?pid=000000000030247578.

[3] British Standards Institution. (2018). Aerospace series. Requirements for

advanced product quality planning and production part approval process.
British Standards Institution, BS EN 9145. UK: British Standards Institution.

Construction Product Quality Planning (CPQP) Control Plan Guideline 26

Appendices

Appendix A – Tool Templates

Templates to be used within the context of this
guideline are available, please contact:
cpqp@constructioninnovationhub.org.uk

Table 2 and Table 3 show a standard Control Plan

template and a PFMEA template, respectively.

Construction Product Quality Planning (CPQP) Control Plan Guideline 27

 Control Plan Control Plan Number

Processes/Operations
Location
Covered
Manufacturer PFMEA
Project
(FMEA Owner) Number

Process Flow Chart

Location
References
Customer Date

Project Description

Team Revision

Part Name Part Number Rev Name Position Email Summary: Revision Notes:

Process/
Process/ Process Key
Op Failure Mode Tool/Machine Used Control Method Tolerance Evaluation Technique Reaction Plan
Opperation Description Revision Characteristic
Number

Table 2. Control Plan Template

Construction Product Quality Planning (CPQP) Control Plan Guideline 28

Construction Product Quality Planning (CPQP)

Table 2. PFMEA Template

Project Description

Project
Part Name

Process Failure Mode Effects Analysis (PFMEA)

Op. No.

Operation/Process Step

Requirements/Expected
Outcome

Part Number
Potential Failure Mode

Potential Failure Mode

Effect

SEV

Rev
Classification
Control Plan Guideline

Name

Customer

(FMEA Owner)
Manufacturer
Team
Potential Failure Mode
Cause

OCC
Current Process Controls

Prevention of Potential
Failure Mode Cause

Position
Detection of Potential
Failure Mode Occurrence

DET

RPN
Email

Location

Location
Recommended
Recommendations

Improvements/Corrective
Actions

Action Owner

Target Completion Date

Summary:

Process Flow Chart

Processes/Operations
References

Covered

Responsible Business/
Department

Actual Improvement/
Corrective Actions
Implemented

Actual Completion Date

Revision Notes:

Revision

Date

Number
PFMEA
Action Results

SEV

OCC

DET
Page 1 of

RPN

Additional Notes and

Considerations
29
Appendix B – List of Abbreviations Appendix C – Glossary of Terms
The following is a list of initialisations and The following is a list of commonly utilised
acronyms used in this guideline. quality, manufacturing and construction
specific terms and their definitions within
C CC Critical Characteristic
this context used within this guideline.
CP Control Plan

CPQP Construction Product Quality Planning C Control Plan (control plan)

BS EN 9145 [3]: “Documented description linking
D DFMEA Design Failure Mode and Effects Analysis manufacturing process steps to key inspection
and control activities. The intent of a control plan
F FMEA Failure Mode and Effects Analysis is to control the design characteristics and the
process variables to ensure product quality.”
P PFMEA Process Failure Mode and Effects Analysis
Construction Product Quality Planning (CPQP)
R RPN Risk Priority Number An adaptation of Advanced Product Quality Planning
(APQP) that is aimed at those enterprises that will feed
S SC Significant Characteristic construction with new componentry for offsite builds.

U UC Unclassified Characteristic Critical Characteristic (CC)

An attribute or feature whose non-conformance
would result in loss of primary function of the product
resulting in catastrophic or hazardous failures without
any warning. These are failures that would potentially
lead to loss of life and/or irreparable damage.

D Detection Control
Measures put in place to detect the failure mode
after the failure has occurred but before the
product is released to the downstream process.

Design Failure Mode Effects Analysis (DFMEA)

An application of Failure Mode Effects
Analysis (FMEA) for product design.

K Key Characteristic (KC)

BS EN 9145: “An attribute or feature whose variation
has a significant influence on product fit, performance,
service life or producibility; that requires specific
action for the purpose of controlling variation.”

P Process Failure Mode Effects Analysis (PFMEA)

An application of Failure Mode Effects Analysis
(FMEA) for process design and implementation.

Prevention Control
Measures put in place to stop or reduce the
likelihood of the failure mode from occurring.

R Reaction Plan
A Reaction Plan is a plan that introduces the required
actions to prevent producing an unconventional product
and non-verified operations. It also demonstrates the
containment plans for detected non-conforming process.

Construction Product Quality Planning (CPQP) Control Plan Guideline 30

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