Using the accepted elements on the control plan the following should be included
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Vishwadeep KhatriPosted February 15, 2019 Vishwadeep Khatri
Posted February 15, 2019 Q. 136 What is the best way to create a Control Plan for a process?
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Vastupal VashisthPosted February 19, 2019 Vastupal Vashisth
Posted February 19, 2019 Control plan is a quality document which is part of PPAP and its a method for documenting all the functional elements in the process to assure quality standards are met for the desired product or output of that process.
The best way to create a control plan is its development by the cross functional team, that has the understanding of the process which we are going to execute or controll. With the help of CFT, we can identify opportunities for improvement. Control plan is more than just a document, it is that plan which is created by or developed by the CFT team to control the process form input to output and ensure that the process produces quality output/products that meet the customer requirement.
CFT team should consider observation/output/know-how from following to create a good control plan.
Control plan must be living document because all the information and problem history changes throughout the life cycle of the process. We should continuously update control plan as per input form any process step or something new happened which was not there earlier. Link to commentShare on other sitesMore sharing options...
Venugopal RPosted February 18, 2019 Venugopal R
Posted February 18, 2019 Benchmark Six Sigma Expert View by Venugopal R
Let me attempt to narrate the unfolding of my understanding of control plan over past 3 decades….
Maybe, my first introduction to the term “control plan” was through ISO 9000 standards released during the late eighties.
However, I had worked with an auto ancillary prior to that, where we had a collaboration with a Japanese organization for setting up manufacturing of an auto component, that I believe was for the first time in India. As part of the technology transfer, one of the key documents that we received was a lengthy, multiple folded, handwritten, tabulated document with all the process steps outlined, the quality characteristic for each stage of the process, the specifications, the method for evaluating compliance to the characteristic, and the sampling recommendations. I am not sure whether this document was named as “control plan” at that time, but I always remember this document, during subsequent stages of my career when I formally got introduced to control plan and whenever I associate with control plan.
This only proves that this tool, whatever it might have been named in those days, was part of the good Japanese production practices, from very early times. And, more importantly, it found its place among ‘most important’ documents required for a technology transfer.
Subsequently, the automotive industry came up with a set of QS9000 standards, along with which emerged the APQP (Advanced Product Quality Planning) standard. The APQP provides a good framework that gives clarity about the creation of Control plan and its linkages and sequence with respect to other methodologies.
The APQP goes through five phases after a pre-planning phase 1. Plan & Define 2. Product Design & Development 3. Process Design & Development 4. Product & Process Validation 5. Feedback assessment & corrective action
The Product Design & Development section includes DFMEA and Design verification plans. The Process Design & Development phase includes PFMEA and the proto control plan formation begins here. The Process and Product validation phase includes the Evaluation Methods, MSA, setting up Statistical Process Controls, all of which are inputs into the control plan. The Production Control Plan is an output of the APQP at Phase 4.
It is evident from this approach that 'control plan' needs to have plan for:
If we need to have dependable control plans for all the above, the inputs for the control plan has to evolve from the above-mentioned phases of APQP.
Some of you may wonder why control plan should be seen only from the context of a Quality System associated with auto industry. It is for the conceptual clarity that may be obtained from the framework of APQP and how the control plan gets derived. The same concept can be adopted for any industry, including Information Technology services.
The control plan will remain as a live document that will keep getting updated in line with the levels of knowledge maturity.
I conclude by saying that although the concept of control plan has existed even several decades ago, we have many avenues that have brought very refined clarity on the pre-requisites, building and executing a control plan effectively. 1 Link to commentShare on other sitesMore sharing options...
Hari Shyam GuptaPosted February 19, 2019 Hari Shyam Gupta
Posted February 19, 2019 Control plan is a document that provides the list of measurements, inspection and quality checks to be done through the process at different phases so that it conforms to the required specifications and reduces the possibility of non conforming output. It saves cost of processing and time and cost of rework.
Control plan can be developed be following procedure.
1. Review the PFD (Process Flow Diagram). 2. Review DFMEA 3. Review PFMEA 4. Review special characteristics matrix. 5. Review lessons learnt documents. 6. Brain storm within the team. Link to commentShare on other sitesMore sharing options...
Rupinder NPosted February 19, 2019 Rupinder N
Posted February 19, 2019 The chosen best answer is that of Vastupal. Read Hari Shyam's answer for a very succinct overview of how a control plan can be developed. What does control plan include?A control plan is a living document that outlines the methods taken for quality control of critical inputs to deliver outputs that meet customer requirements. It also provides a written description of the measurements, inspections, and checks put in place to control production parts and processes.
What are the three elements of a control plan for a process?What are the three elements of a control plan for a process? Process map, control charts, calibration plan. ... . What are all of the elements included in the monitoring plan portion of a control plan? ... . How would you describe a process that is out of statistical control but always producing conforming product?. What is the control plan in Six Sigma?What is A Six Sigma Control Plan? In the world of quality management, a control plan is a written summary of the process that lays out in detail the steps to be taken to maintain a process or a device operating at the current level of performance.
What can a control plan include as you plan the effort in question?Typically, the control plan may also include other items like: the frequency with which the process is reviewed, verification that the measurement system is capable, typical corrective actions to be taken in the presence of out-of-control conditions, any special inspection requirements, and a history of the process ...
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