The Control Plan, 1st edition manual, provides clarification on various requirements, further explanation on linkages to APQP processes, and detailed guidance on how to develop control plans, along with industry best practices for effectively using these plans. Additional updates include the introduction of a "Safe Launch" requirement to control plan phases, examples of developing plans for highly automated manufacturing applications, guidance on using software to develop and manage control plans, and revised examples, tables, forms, and checklists for additional support.
Foreword
Introduction
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0.1 Purpose of this Manual
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0.2 Support to Product Quality Planning Cycle
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0.3 Control Plan Through the Product Life Cycle
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0.4 Control Plan Methodology
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0.5 Control Plan in Overall Quality Process
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0.6 Manual Structure
Chapter 1 : Control Plan Requirements and Guidelines
Introduction
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1.1 Control Plan Format
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1.2 Special Characteristics
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1.3 Pass-Through Characteristics (PTC)
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1.4 Error-Proofing Confirmation
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1.5 Families of Control Plans
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1.6 Interdependent Processes and/or Control Plans
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1.7 Rework and Repair Processes
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1.8 Reaction Plan Details
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1.9 100% Visual Inspection
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1.10 Black-Box Processes
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1.11 Non-Design Responsible Organizations
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1.12 Directed Supply
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1.13 Use of Software to Develop and Manage Control Plans
Chapter 2 : Control Plan Development
Introduction
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2.1 Getting Started
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2.2 Timing and Coordination between APQP and CP Teams
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2.3 Inputs (Numbers Indicate Section in APQP Manual)
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2.4 Outputs (Numbers Indicate Section in APQP Manual)
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2.5 Form Fields
Chapter 3 : Control Plan Phases
Introduction
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3.1 Prototype Control Plan
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3.2 Pre-Launch Control Plan
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3.3 Production Control Plan
Chapter 4 : Effective Use of Control Plans
Introduction
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4.1 Reverse PFMEA
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4.2 Using Software to Develop and Manage Control Plans and Related Documents
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4.3 Layered Process Audits as Control Plan Verification
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4.4 Control Plans in Highly Automated Processes
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4.5 Using Family and Foundation FMEAs
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4.6 Control of Storage and Handling Related Risk
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4.7 Abnormality Management in Relation to Control Plans
Appendix A : Control Plan Examples
Introduction
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A-1 General Example
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A-2 Process Dependent Examples
Appendix B : Forms and Checklists
Introduction
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B-1 Control Plan Form
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B-2 Control Plan Checklist
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B-3 Special Characteristics Worksheet
Appendix C : Reference Material
Appendix D : Sector Specific Guidance
Appendix E : Glossary
Appendix F : Index
