Delphi Comprehensive Control Plan

Comprehensive Control Plan
Training
CCP 4/03 HK
Energy & Chassis Systems
Contents
Introduction
The
Comprehensive Control Plan

Elements of a Comprehensive Control
Plan
CCP 4/03 HK
Introduction
Quality
is designed into a product

through the Advanced Product Quality
Planning (APQP) process
APQP assures that customer requirements
are not lost in product and process design
APQP aims at minimizing variation through
better design and through process
controls
CCP 4/03 HK
Introduction
Customer Requirements:
Char. Verification Matrix (CVM)
Product Definition:
Characteristics: KPC's, QCI's,

DFMEA
Process Definition:
Process Flow Dia. (PFD), KCC's,
Failure Mode Analysis:

PFMEA,
Lineside Review Process
Control Strategy:
Comprehensive Control Plan,

Errorproofing
Manufacturing:
Process Monitoring,
Standard Cell, Layered Audit
CCP 4/03 HK
Introduction
PHASE
PRODUCT
ENGINEERING
MANUFACTURING
ENGINEERING
Define & Analyze Requirements
MANUFACTURING
OPERATIONS
PFD
QCI
QCI
KCC
Process Monitoring Plan
KCC
Service Life/
Durability
Customer Interface
C/O Checklist
KPC
QCI
Peformance
CVM
INPUTS
OUTPUTS
DFMEA
Testing Online
Preventive Maintenance
Gage Instruction
Errorproofing
Verification
Dept._________
KPC
QCI
Standard
PFMEA
First Time Quality
Drawings &
Specifications
CONTROL PLAN
KCC
KCC
QCI
QCC
SPC
SCC
Control
Strategy
Control
Strategy
Control
Strategy
VARIABLE
ATTRIBUTE
GO
NO-GO
CCP 4/03 HK
Introduction
Development
of a control plan is an
integral part of the Advanced
Product Quality Planning process
a control plan is one of the final outputs
of APQP
CCP 4/03 HK
Introduction
A comprehensive control plan is a written

summary of the methods and systems used
to control production parts and processes
addresses all product and process
characteristics and requirements for control.
monitors Process Stability
includes FTQ
aims at minimizing variation
Prevents defects from escaping the
manufacturing operation
CCP 4/03 HK
Introduction
Comprehensive Control Plan - Justification
- According to QS9000 Third Edition ( Pages 40 & 41)
Final Inspection & Testing 4.10.4

The Quality Plan ( Control Plan) and/or documented procedures
for final inspection and testing shall require that all specified
inspection and tests have been carried out and that the results
meet specified requirements.
Layout Inspection & Functional Testing 4.10.4.2
A layout inspection and a functional verification ( to applicable
customer engineering material and performance standards) shall be
performed for all products at a frequency established by the
customer (see Section II). Results shall be available for customer
review.
CCP 4/03 HK
Introduction
Comprehensive Control Plan Justification
(Continued)
Final Product Audit 4.10.4.2
The supplier shall conduct audits of packaged final
product to verify conformance to all specified requirements
( e.g. product, packaging, labeling) at an appropriate
frequency. Note: This activity, also known as a dock audit
is based upon sampling and is generally performed after final
inspection but prior to shipment.
CCP 4/03 HK
Introduction
APQP
calls for three (3) types of

control plans
prototype control plan
pre-launch control plan
production control plan
CCP 4/03 HK
10
(1) Prototype Control Plan
Introduction
Requirement:
dimensional measurements and functional tests on
prototype builds
process parameters that affect product
characteristics
Purpose:
to validate the prototype product
to validate the prototype process
a good way to find and fix real problems prior to
production tooling being made
Can provide input to Customer Verification Matrix
(CVM) Supplier Input Form
CCP 4/03 HK
11
Introduction
(2) Pre-Launch Control Plan
Comprehensive
Requirement:
includes dimensional measurements and
functional tests on early production parts
additional controls to be in place until the
process is validated
Purpose
to protect the customer from potential
quality issues during early production
to check the process prior to and during
start of production
CCP 4/03 HK
12
Introduction
(3) Production Control Plan (Comprehensive)
Requirement:
systems for controlling parts and processes

includes receiving inspection, manufacturing
processes, assembly, packaging, labeling, etc. as
applicable ( Dock to Dock)
Purpose
to provide a product to the customer that meets

or exceeds quality requirements
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13
The Control Plan Process
Identify a core team and appoint a leader

Manufacturing Engineering owns control plan prior to
Start of Production ( SOP).Quality owns updating
it after SOP
need representatives from groups involved in
product design, process/tool engineering, industrial
engineering, gauging, quality, supplier quality,
manufacturing personnel, etc.
train team if necessary
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14
Understand the product requirements

Characteristics Verification Matrix
where KPCs and QCIs first identified
Supplier Input Form
System and/or Design FMEA

information from design reviews
lessons learned, warranty info, customer
complaint information from similar products
information on how the customer is going to test,
measure and use the product
CCP 4/03 HK
15
Understand the manufacturing process

Characteristics Verification Matrix
where KCCs and QCCs first identified
Process Flow Diagram

learn about steps that involve rework or scrap
learn about incoming component quality
Process FMEA
information from similar processes, such
as,Design of Experiments ( DOE), capability, first
time quality, etc.
CCP 4/03 HK
16

Define
characteristics to be controlled
and methods for controlling them
if CVM available, characteristics to be controlled
are defined here
consider all process steps as listed in Process Flow
Diagram for input and output information
paretoize RPNs on the PFMEA to help understand
high risk processess
include all KPCs, QCIs and standard product
characteristics designated by the customer or
internally(Prints, Specifications, Math Data)
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17
- Each part drawing characteristic or
requirement must be numbered and have its

corresponding number identified in the
Control Plan. If the total number of drawing
requirements is greater than 20, it is
acceptable to group drawing numbers that will
be checked at the same defined frequency
into a single entry on the control plan.
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18

- Drawing characteristics include physical
requirements ( KPC, weight, volume,
appearance) , structural requirements
(porosity,cracks,voids,hardness),
performance requirements ( dielectric
integrity, leak, adhesion), and packaging &
labeling requirements.
- Sample size & frequency must be based on
variation exhibited ( e.g. part to part, operator
to operator, lot to lot, set-up to set-up)
CCP 4/03 HK
19

-
The minimum standard for assuring

compliance of special characteristics is a first
and last piece inspection/test of the special
characteristics
- All control methods must be traceable to
control activity to maintain stable & capable
output. (e.g. die held dimension requires
defined die P.M. or tool requires defined level
of tool change based on wear.
- Control activity monitored through FTQ
CCP 4/03 HK
20
CONTROL PLAN
Control Plan Category
Key Contact Name
Prototype
Pre-Launch Production
Control Plan Number
Key Contact Phone
123456789
248 813-3000
Part Number
Date (Orig)
ECL
Date (Rev)
3/2/2003
John Doe
Page
3/31/03
Customer Engineering Approval (If Req'd)
Date (If Req'd)
Supplier / Plant Approval / Date
Customer Quality Approval (If Req'd)
Date (If Req'd)
Other supplier approval by (If Req'd)
Other Approval (If Req'd)
Date (If req'd)
12
123456789
Part Name / Description
Measurement Assy.
Supplier / Plant
Supplier Code
ACME / Plant 1
Other Approval Date (If Req'd)
00908090
Core teamM embers
Control Plan Example with Grouping of some Product Characteristics on Control Plan
Characteristics
Part /
Proc
#
12
20
Process
Name /
Operation
description
End of Run
Inspection
Annual Layout
CCP 4/03 HK
Machine,
Device,
Jig, Tools
For Mfg.
No.
Product
Process
Methods
Special
Char.
Class.
Product /
Evaluation /
Process
Sampl Sample
Measurement
Specification
e Size Freq.
Technique
/ Tolerance
Inside
Diameter
QCI-3
13.01 +/0.06
Outside Dia.
QCI-4
16.0+/-0.1
Gage 2563m02 1 pc Once

Measure &
per
per
Record
cavity shift
Control Method
Reaction
Plan
P12-01
P13-01
Process sheet
Contain
Material/ Fix
process
1 pc Once
per
per
cavity shift
1 thru See Annual

5
Layout Sheet
CMM
Fixture xyz
Measure &
Record
separately
Low, Avg, Hi
See Annual See Annual
Layout Sheet Layout Sheet
1 pc Once
Annual Layout
per
per year Sheet
cavity
P20-01
8 thru See Annual

30
Layout Sheet
See Annual See Annual

Layout Sheet Layout Sheet
1 pc Once
Annual Layout
per
per year Sheet
cavity
P20-01
21
CONTROL PLAN
Key Contact Name
Prototype
Pre-Launch
Control Plan Number
Key Contact Phone
123456789
248 813-3000
Part Number
Date (Orig)
John Doe
Production
ECL
Date (Rev)
3/2/2003
Page
3/31/03
Date (If Req'd)
Date (If Req'd)
Date (If req'd)
12
123456789
Measurement Assy.
Supplier / Plant
Supplier Code
ACME / Plant 1
00908090
Core team M embers
Control Plan Example with All Numbered Product Characteristics listed on Control Plan
Characteristics
Process
Part /
Name /
Proc
Operation
#
description
12
End of Run
Inspection
20
Annual Layout
CCP 4/03 HK
Machine,
Device,
Jig, Tools
For Mfg.
No.
Product
Process
Methods
Special
Char.
Class.
Product /
Evaluation /
Process
Measurement
Specification
Technique
/ Tolerance
13.01 +/Gage 2563m02
0.06
Measure &
Record
Inside
Diameter
QCI-3
Outside Dia.
QCI-4
Length
85.0 =/-0.8
Champher
0.5 x 45 Dg.
CMM
Fixture xyz
Flange Width
30.0 +/-0.8
Calipers
Flange
Thickness
10.0 +/- 0.8
Calipers
16.0+/-0.1
22
CMM
Fixture xyz
Measure &
Record
separately
Low, Avg, Hi
Caliper
Sampl Sample
e Size Freq.
Control Method
Reaction
Plan
1 pc
Once
per
per
cavity shift
P12-01
P13-01
1 pc
Once
per
per
cavity shift
Process sheet
Contain
Material/ Fix
process
1 pc
per
cavity
1 pc
per
cavity
1 pc
per
cavity
1 pc
per
cavity
Once
Annual Layout
per year Sheet
P20-01
Once
Annual Layout
per year Sheet
P20-01
Once
Annual Layout
per year Sheet
P20-01
Once
Annual Layout
per year Sheet
P20-01
Elements of a Control Plan
4 Main Sections
Header Information
1
Product/
Product/
Process
Process
Description Characteristics
CCP 4/03 HK
23
Control
Methods
Reaction
Plan

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
-- Product/Process Description --
This
section identifies all parts/components and

associated process steps that are in need of
control.
CCP 4/03 HK
24

1
Part/Process
Number
reference number to the Process Flow Diagram

e.g. process step 10 on PFD must link with PFMEA
and Control Plan
Process Flow Diagram is the foundation for process
numbering
there should be no ambiguity
CCP 4/03 HK
25

1
Process
Name/Operation Description
describe the operation or process step

concisely
the description should match the
description in the Process Flow Diagram
recommended that you use the format
verb+object
e.g. load hopper; move parts to assembly area
CCP 4/03 HK
26

1
Machine,
Device, Jig, Tools for

Manufacturing
identify the machine used in the process
step
be specific: if only certain machines out
of many are used for this part, identify
the specific machines in the control plan
e.g. mold machines #15,16,17
CCP 4/03 HK
27

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
Section 2
Contains a detailed description of the specific characteristics
that must be controlled in order to assure quality.
Must identify product and process characteristics separately
-not on the same line
Each component and/or process step listed in the previous
section, Product/Process Description, might have several
characteristics that need to be controlled.
CCP 4/03 HK
28

Header Information
1
Number
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
cross-reference number to a product or

process characteristic on a drawing,
sketch, process flow diagram, FMEA, or
other applicable document
adds more detail to the part/process number
applicable drawings and flow diagrams should
be easily tracked from the control plan
there should be no ambiguity
CCP 4/03 HK
29

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
Product Characteristics
features, attributes, or properties of a part,
component, or assembly
examples:
CCP 4/03 HK
dimensions, weights, geometrical attributes

appearance items such as gloss
material-related characteristics such as hardness
etc.
30

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
Process Characteristics
process variables and parameters that have a

cause and effect relationship with product
characteristics
can only be measured at the moment it occurs
examples:
mold temperature
cycle time
CCP 4/03 HK
31
Fishbone diagrams are a useful tool to help

identify process parameters that have an effect
on product characteristics
man
machine
process char
process char
Product
Characteristic
process char
method
CCP 4/03 HK
material
32

There
is often a complex relationship

between product and process
characteristics
one product characteristic affected by
more than one process characteristic
several product characteristics affected
by one process characteristic
CCP 4/03 HK
33
-- Product/Process Characteristics -
Special Characteristics
(KPCs and KCCs, QCIs and QCCs) must be
included and designated by the appropriate
symbol or text in the control plan Special
Characteristics Classification column
Format on Control Plan

Each product or process characteristic must be
listed on a separate line in order to maintain
continuity with the rest of the information
listed on the plan
CCP 4/03 HK
34
-- Control Methods --
Header Information
1
Product/
Product/
Process
Process
The
Control
Methods
Reaction
Plan
Control Methods section includes the:
product/process specification and tolerance

evaluation/measurement technique
sample size/frequency
control method
CCP 4/03 HK
35

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
Product/Process
Specifications/Tolerances
identified for the characteristics that are to
be controlled in Section 2
obtained from engineering drawings, process
specifications, material standards, assembly
requirements, etc.
CCP 4/03 HK
36
Evaluation/Measurement Technique
Many different types
. dimensional Measurement
. functional Gaging
variable or attribute gaging

on-line or off-line testing
visual inspection
error proofing
use of Test/Gage Set-up Masters must be listed in
Control Plan
Short description or reference number:

measurement gages, fixtures, etc.
measurement procedures
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37
Error Proofing
Two types of Error Proofing

Error Prevention
Error Detection
Error Prevention
Error cannot occur by design or process
Error Detection
Detection at the source
Detection downstream
visual inspection
on-line testing/gaging
CCP 4/03 HK
38

--Control Methods-
Evaluation/Measurement Techniques
Measurement System Analysis must be performed

on any measurement system used for controlling
product quality
Measure whatever characteristic (product or
process) that will be used for control
Linearity, repeatability, reproducibility,stability &
accuracy maybe required to qualify measuring
equipment
For attribute measurement methods, repeatability
and reproducibility must also be assessed
CCP 4/03 HK
39
Sample
Size and Frequency
used for Lot Control of Special

Characteristics
examples
CCP 4/03 HK
1st and last piece

5 pcs every hour
1st piece after setup/change over
100% ongoing
First piece after preventive maintenance
40
Things to consider when determining sample size and

frequency:
What is the process capability?

What is the production rate/hour?
How many cavities or dies are there?
What is the standard pack quantity?
At what frequency are parts going to be shipped?
What is the buffer size?
How long does the inspection or test take?
Does the sampling plan make sense? Does it address the primary
family of variation? (e.g. within part, part to part, setup to setup,
shift to shift, material lot to material lot, time to time, etc.)
CCP 4/03 HK
41
AIM IS TO:
ASSURE TIMELY PROCESS

FEEDBACK TO PREVENT POOR
QUALITY WHILE
MINIMIZING ANY
POTENTIAL RISK TO THE
CUSTOMER
CCP 4/03 HK
42
Control
Method
this column contains a description of how

the operation will be controlled, including
procedure numbers where it applys
the control method utilized should include
the documentation form that is used to
record the results of the characteristic
being evaluated or measured
CCP 4/03 HK
43
-- Control Methods -Examples of control method documentation

include:
CCP 4/03 HK
Process Monitoring Check Sheets

Statistical Process Control forms
Off-line test records
Receiving Inspection records
Error Proofing Verification documentation
Preventive Maintenance records
Calibration records
44
The control method should be continually

evaluated for effectiveness by performing:
Line Side Review
Prior to PPAP to verify no documentation gaps
in process flow/ control plan/ pfmea/ work
instructions. Include all characteristics of part
or material.
Observe from plant floor ( See Line Side
Review Training).
CCP 4/03 HK
45
The control method should be continually

evaluated for effectiveness by monitoring:
process capability
control charts
process monitoring data sheets
first time quality data
continuous improvement efforts document on
gate chart
process stability monitoring alarm limits &
reaction plan
audit data
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46

Header Information
1
Product/
Product/
Process
Process
Control
Methods
Reaction
Plan
Reaction Plan
corrective action to be performed to prevent
nonconformances from reaching the customer
prefer actions that keep the process in control
be sure to mark and quarantine nonconforming
product (according to procedures)
document what corrective action was taken on
appropriate form
CCP 4/03 HK
47

Update
the control plan as the

product or process changes, or as new
issues emerge
the control plan is a living document
throughout the product life cycle
CCP 4/03 HK
48
Control Plan Example

Form 818-1 (Rev 12Apr02)
Prototype
Pre-Launch
CONTROL PLAN
Production
Part Number/Latest Change Level
Key Contact/Phone
Control Plan No:

Date (Orig.)
Customer Part Number

ACME XYZAA
Part Name/Description
End-Cap (Machined State)
Supplier/Plant
Supplier Code
Core Team
Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Approval/Date
Customer Quality Approval/Date (If Req'd.)
Other Approval/Date (If Req'd.)
Other Approval/Date (If Req'd.)
Characteristics
Process Name/
Op-Seq
Operation
No.
Description
Machine,
Device, Jig,
Tool for Mfg.
10-6
Turn End-cap
10-6
Turn End-cap
CNC Lathe
10-6
Turn End-cap
10-6
30-5
No.
Product
Methods
Process
End-cap
Special
Char.
Class
Product/Process
Specification/
Tolerance
Evaluation
Measurement
Technique
QCI 4 Diameter
18 +/- 0.05 mm
Calipers
Turning speed
QCC 4 500 +/- 10 RPM
Speed Sensor
CNC Lathe
Turning speed
setpoint
verification
QCC 4 500 RPM
Visual
Turn End-cap
CNC Lathe
Cutter Life
Drill Hole
CNC
CPTraining.ktm.ppt
Key-chain hole
Date (Rev.)
Must be replaced every Machine Counter

4000 pieces max
QCI 1 3.0 +/- 0.1 mm
49
Plug gages
(attribute check)
Sample
Size
5
100%
Freq.
Control
Method
Reaction
Plan
Every two hours
X-R chart
Perform
troubleshooting
procedure,
contain parts
since last check
if required
Continuous
CNC Controller
Run diagnostics
and perform
maintenance
Correct setting
and contain
previous parts
for
measurement
Start of shift,
Process
changeovers,
Monitoring
maintenance (end Worksheet
of shift if less than
3-shift operation)
Maximum of 4000 Process

pieces
Monitoring
Worksheet
Change tool
Every two hours
Perform
troubleshooting
procedure,
contain parts
since last check
if required
Process
Monitoring
Worksheet
C
o
n
t
r
o
l
CONTROL PLAN
Key Contact Name
Prototype
Pre-Launch
Production
Control Plan Number
John Doe
Key Contact Phone
123456789
ECL

Supplier Code
ACME / Plant 1
Date (If Req'd)
Date (If req'd)
Measurement Assy.
Supplier / Plant
Page
3/31/03
Date (If Req'd)
12
123456789
Date (Rev)
3/2/2003
248 813-3000
Part Number
Date (Orig)
00908090
Core team Members
2 Examples of showing FTQ monitoring at a station level. This FTQ would be an indication of the process stability.
Characteristics
Part /
Process Name /
Machine, Device, Jig,
Proc # Operation description
Tools For Mfg.
10
Torque assembly Assy. Ststion

to body
111
No.
Product
Process
Leak Rate
QCI
Leak Tester
FTQ
OR
FTQ
CCP 4/03 HK
Special Char.
Class.
P
l
a
50n
QCC
Product / Process
Specification /
Tolerance
Methods
Evaluation /
Sample Sample
Measurement
Control Method
Size
Freq.
Technique
Reaction Plan
200 SCCM Max. LEAK TESTER 100% Conti

nuou
s
Pass/ Fail
2
Shift Process sheet
Masters
Alarm Limits
Visual count
1
Hr
Tally Sheet
8max. /2min. per
hour
Place rejects into FTQ

reject cart
Refer to FTQ
010 for limits
FTQ Reaction Plan

FTQ 010
Visual count
Hr
Tally Sheet
Contain Material/ Fix

process
FTQ reaction plan
FTQ-010
Comprehensive
Control Plan
C&R
CONTROL OR
MONITOR
INSPECT/CHECK
TEST
AUDIT
OK/NOT OK STD
CONTAIN & REACT
All Product and Process checks

are verified prior to lot release
RECEIVE
OK
C&R
MANUFACTURE
Y
PRODUCT
PACK
LABEL
OK
C&R
OK Y
C&R
PRODUCT
FIT
FORM
FUNCTION
PERFORMANCE
PROCESS
TOOL
EQUIPMENT
MEASUREMENT
SETTINGS
OPERATOR
Y
MACHINE
C&R
LOT
OK
PACK
SHIP
OK Y
Y
C&R
OK
C&R
QUANTITY
PRODUCT
PACK
FIT
LABEL
FORM
FUNCTION
MAINTENNANCE
PERFORMANCE
TOOL
PROCESS
TOOL
EQUIP
EQUIPMENT
MEASUREMENT
MEASURE
SETTINGS
OPERATOR
QUANTITY
PACK
LABEL
OK
C&R
SYSTEM VERIFICATION/AUDIT
POLICIES
PROCEDURES
INSTRUCTIONS
OK
METHOD
CCP 4/03 HK
C&R
MAN
MATERIAL
LOT ASSURANCE
51

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What is the purpose of a comprehensive control plan?

What is the purpose of a comprehensive control plan?

What are the elements of a comprehensive control plan according to the document?

What are the elements of a comprehensive control plan according to the document?

Comprehensive Control Plan

Energy & Chassis Systems

Comprehensive Control Plan

Energy & Chassis Systems

is designed into a product

Energy & Chassis Systems

Characteristics: KPC's, QCI's,

Failure Mode Analysis:

Comprehensive Control Plan,

Energy & Chassis Systems

Define & Analyze Requirements

Process Monitoring Plan

First Time Quality

Energy & Chassis Systems

Energy & Chassis Systems

A comprehensive control plan is a written

Energy & Chassis Systems

Final Inspection & Testing 4.10.4

Energy & Chassis Systems

Energy & Chassis Systems

calls for three (3) types of

Energy & Chassis Systems

(1) Prototype Control Plan

Energy & Chassis Systems

(2) Pre-Launch Control Plan

Energy & Chassis Systems

systems for controlling parts and processes

to provide a product to the customer that meets

Energy & Chassis Systems

The Control Plan Process

Identify a core team and appoint a leader

Energy & Chassis Systems

The Control Plan Process

Understand the product requirements

System and/or Design FMEA

Energy & Chassis Systems

The Control Plan Process

Understand the manufacturing process

Process Flow Diagram

Energy & Chassis Systems

The Control Plan Process

Energy & Chassis Systems

The Control Plan Process

- Each part drawing characteristic or

requirement must be numbered and have its

Energy & Chassis Systems

The Control Plan Process

Energy & Chassis Systems

The Control Plan Process

The minimum standard for assuring

Energy & Chassis Systems

Control Plan Category

Key Contact Name

Control Plan Number

Key Contact Phone