1. DSQR Training Control Plans
HEATING, COOLING & WATER HEATING PRODUCTS
DSQR Training Control Plans
Bill Kennedy
Corporate Quality

2. Control Plan Training Methodology
For process control and improvement to be effective, a
basic understanding of the process must be obtained. A
multi disciplined team should be established to develop a
Control Plan by utilizing all the available information to gain
a better understanding of the process, such as:
process flow diagram
system/design/process failure mode and effects analysis
special characteristics
lessons learned from similar parts
team’s knowledge of the process
design reviews

3. Control Plan Training Methodology
What is a Control Plan?
A structured approach for the design, selection, and controlled
methods used in producing a part.
A Control Plan defines the operations, equipment, materials,
processes, methodologies and CTQ’s integral to the manufacturing
process. Control Plans are critical for planning a robust process.
Control Plan should:
List all the sequence and type of operations used in the process
Must address and include the CTQ’s
Include specifications, sampling strategy, control and reaction plans
Include periodic conformance testing and product verifications
Type and method of process and inspection equipment used

4. Control Plan Training Methodology
The primary intent of Control Plans is to ….
create a structured approach for control of the process and product characteristics, while focusing the organization on characteristics important to the customer.
assure well thought-out reaction plans are in place in case an out-of control condition occurs and provides a central vehicle for documentation and communication of control methods.
describe the sequence of process steps, methods, and actions required at each phase of the process including receiving, inprocess, out-going, to assure that all process outputs will be in a state of control.

5. Control Plan Training Methodology
Control Plans
Can be developed independently, but are a natural extension of
an FMEA
Assures a system is in place to control the risks of the same failure
modes as identified in the FMEA.
Special attention is typically given to potential failures with high
RPNs and those characteristics that are critical to the customer.
Inputs necessary to develop a Control Plan are:
Technical specifications and drawings
Process flow diagram
DFMEA/PFMEA
Details of measurement methods, equipments, fixtures, machines
Sampling requirements and frequency, if any
Reaction plans

6. Control Plan Training Methodology
Benefits of a Control Plan include:
Quality
Formal structure provides a thorough definition and evaluation of the product and process.
Describes the actions required at each phase of the process to ensure all process outputs will be in control
Identifies key process characteristics and helps to monitor sources which can cause variation in product characteristics.
Customer Satisfaction
Control Plans focus internal resources on processes and products related to characteristics that are important to the customer.
Communication
As a living document Control Plan identifies and communicates changes in the product/process characteristics, control method, and characteristic measurement.

7. Control Plan Training Development
Steps for control plan development
Describe the process
Finalize the characteristics to be controlled
Plan the proper method of control
Establish the reaction plan

8. Control Plan Training Typical Control Plan Format
Page of
Supplier Name:
Control Plan Number
Control Plan Revision Level
Sup
plier Key Contact/Phone
Written by
Date of last revision
Delta Part Number
Delta Part Revision Level
Part Name
Delta approval
Approval date
Process
Number
Process Name/ Operation
Description
Machine, device, jig, tools,
make, model, asset #, etc
Characteristics
Methods
Reaction Plan
No.
Product
Product/Process Specification/
Tol
erance
Evaluation Measurement
Technique
(gage # if applicable)
Sample
Control
Method
Size
Freq.
Notes : 1 2 8 13 4 15 16 17 18 19 20 21 22 23 24 25 9 10 3 11 5 7 6 12
Note: Alternate formats can be used if they contain necessary information

9. Control Plan Training Typical Control Plan Format

10. Control Plan Training Typical Control Plan Format

11. Control Plan Training Typical Control Plan Format

12. Control Plan Training Group Exercise:
In the assigned teams and using the information and template
provided develop and draft a Process Control Plan.