Sustain process gains by locking in operational controls and standard inspection routines.
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What is a Process Control Plan in APQP / IATF 16949?
A Process Control Plan documents all process steps, product/process characteristics, specifications, measurement techniques, sample sizes/frequencies, control methods (e.g. SPC charts, poka-yoke), and reaction plans when nonconformances arise.
Direct link: DFMEA → PFMEA Failure Modes → Control Plan Special Characteristics
| Process Step | Characteristic | Specification / Tol | Measurement Tool | Sample Size / Freq | Control Method | Reaction Plan |
|---|---|---|---|---|---|---|
| 10 - CNC Turning | Shaft Outer Diameter (OD) | 25.00 ± 0.02 mm | Digital Micrometer (0.001mm) | 5 pcs / 2 hours | X̄-R Control Chart | Stop lathe, adjust offset, quarantine last 2h batch |
| 20 - Heat Treat | Core Surface Hardness | 58 - 62 HRC | Rockwell C Hardness Tester | 3 pcs / furnace heat | I-MR Control Chart | Quarantine heat batch, conduct metallurgical review |
The Control Plan is the central execution document linking engineering specifications to shop-floor quality inspection routines, ensuring critical product safety and dimensional characteristics are continuously monitored.
Systematically identify potential process failure risks and prioritize preventive engineering actions.
Statistical Process Control (SPC)Detect assignable causes of variation and establish statistical control limits.
Process Capability & Measurement (MSA)Determine whether a manufacturing process complies with customer engineering tolerances and specifications.