With fewer than six months left to complete the transition to iatf 16949. Process control plan pcp james davis, gdls slide number. The last phase which is known as the production plan, all control items in a control plan will be carried out. Apqp advanced product quality planning is a crossindustry quality approach which was originally developed by the us automotive industry. The automotive industry action group aiag is a unique notforprofit organization where oems, suppliers, service providers, government entities, and individuals in academia have worked collaboratively for more than 38 years to drive down costs and complexity from the automotive supply chain. Control plan prototype prelaunch x production key contactphone dateorig. Advanced product quality planning and control plan apqp, reference manual, pb, 1995 chrysler ford gm ai on. Control plan template in excel compatible with aiag standards, excel 20102019 and office 365. Control plan must match the flow chart and pfmea process steps and describe the actions of each phase of the manufacturing process from receiving to shipping. Where sampling is not designated, a supplier may use a statistically. Some of our customers require pfmeas, and control plans for each process.
This is a weak process control step and would produce a high riskprioritynumber on a pfmea. Advanced product quality planning apqp and control plan reference manual copies of this manual can be obtained from the automotive industry action group aiag apqp manual at download free pdf files,ebooks and documents of aiag apqp manual. Are all special product and process characteristics included in the control plan. Process fmea and control plan medical devices harpco systems. A control plan is a written description of the system for controlling parts and processes. Aiag control plan questions was the control plan methodology referenced in section 6 used in preparing the control plan. Elements of control plan lean six sigma green belt. Prototype control plan appearance approval report master sample test results checking aids engineering approval process design and development verification process flow diagrams process fmea prelaunch control plan production control plan measurement systems analysis interim approval initial process studies product and process validation. A single control plan may apply to a group or family of products that are produced by the same process at the same source. In order to implement iatf 16949, the organization needs to develop control plans at the system, subsystem, component, andor material levels for the relevant manufacturing site and all product supplied what is a control plan and when is it used. This manual provides general guidelines for implementing apqp at all phases of new product and services development, from concept to launch.
Gaining a proficiency in apqp demonstrates an individuals understanding of world class product quality planning and control plan guidelines. Characteristics, control plan, spc along with ongoing feedback assessment and corrective action. The automotive industry action group aiag is a unique notforprofit organization where. During production runs, the control plan provides process monitoring and control methods to control characteristics. I hope that someone will be able to help me with my small dilemma on fmea and control plans. Ford dynamic control plan dcp template in excel and more control plan questions control plans by process howard says. Develop a manufacturing system and its related control plans to achieve quality products. The customer who require it are the big oems, and we have all that because it was part of our many ppaps, but some of our customers are aftermarket companies who dont care about iso, iatf, risk analysis, etc. While the control plan example on this page is manufacturing related, the same concept can be adapted to any number of physical or transactional work processes. To aid the manufacturing of quality products by using a structured approach to identify and implement valueadded controls to. After this training, the participants will have an understanding of process flow and aiag vda pfmea structure analysis links between process flow, pfmea, control plan and work instructions process fmea and control plan. The following terms, used in this edition are used to describe the supply chain.
After this training, the participants will have an understanding of process flow and aiagvda pfmea structure analysis links between process flow, pfmea, control plan and work instructions process fmea and control plan. Aiagreference manual apqp advanced product quality planning and control plan aiagreference manual msa measurement systems analysis aiagreference manual spc statistical process control aiagreference manual fmea potential failure mode and effects analysis. Sketches, as necessary, may be attached to the control plan for illustration purposes. The control plan lists all process parameters and part characteristics that require specific quality planning actions. The control plan should have evidence of recent process change history. Have all known customer concerns been identified to facilitate the selection of special product and process characteristics. Process specification tolerance evaluation measurement technique sample control method 0 receive packaging e utility 6 inspection no defects compare to shipper per lot as needed inspection 126 issue ncr mxp100201 0 receive packaging warehous e utility 6 visual inspection. This is a weak process control step and would produce a. Introduction to apqp icdst eprint archive of engineering and. A control plan is a document describing the critical to quality characteristics, the critical xs or ys, of the part or process. The benefits of the apqp or control plan would be a reduction in the complexity of products quality planning for the customers and organizations, and a means for organizations to easily communicate product quality planning requirements to suppliers.
Qa assistant studio max includes apqp software with design fmea software, process fmea software, ppap software, control plan software, process flow chart software, work instruction software, part submission warrants, project planning, and more. Howto guide control plans quality control plan, excel. Actual process observed in factory should match control plan. Control plans must have all the phases present in the business plan in pdf. Control plan guidelines developed jointly by chrysler, ford and general motors. Suppliers gain an understanding of basic industry requirements for achieving part approval from their customer. Critical to quality ctq parameters should be identified in the control plan. Here are the various aiag ppap manual 4th edition forms welcome to the cove.
Supplier quality requirements am general processes utilizing the aiag advanced product quality planning and control plan. Feb 10, 2016 in this live sap demo, we show you how the control plan is used to ensure fmea characteristics are being consumed in an inspection plan. Today i received a question about how to develop a control plan from a pfmea. The tables have been included in the list tab at the bottom for easy reference. A control plan is a method for documenting the functional elements of quality control that are to be implemented in order to assure that quality standards are met for a particular product or service. The purpose of this manual is to communicate to suppliers internal and external and subcontractors. Introduction to production part approval process ppap. Advanced product quality planning and control plan.
Process failure mode and effects analysis, that will ensure product quality in the manufacturingassembly. Walvekar 10242010 4222011 part numberlatest change level core team customer engineering approvaldate if reqd. A control plan is the documented description of those procedures, checks or assigned activities necessary to verify that production units continue to conform to the type approval requirements with regard to specification, marking and performance. Control plan aiag quality assurance production and manufacturing. Through this system of monitoring and control, customer requirements will be met and the product or process variation will be reduced. Discuss aiag vda pfmea transition and implementation plan. The benefits of the apqp or control plan would be a reduction in the complexity of products quality planning for the customers and organizations, and a means for organizations to easily communicate product quality planning requirements to. As far as i understand it dcp is the ford methodolgy, if you look at page 83 of the aiag book, it says that ford is. Certification by aiag in apqpppap verifies an individuals proficiency in product quality planning and control plan guidelines, and ppap submittal requirements as defined in the apqp and ppap reference manuals. This methodology is applicable to a wide range of manufacturing processes and technologies. Since that time, the external suppliers to ford motor company, and internal suppliers within ford have used the fao apqp status reporting guideline to monitor their own systems with regard to apqp.
This course is designed to establish the use of 4th edition process fmeas and to help you learn the skills needed to practice risk reduction and defect prevention. Prelaunch control plan process instructions measurement systems analysis plan preliminary process capability study plan packaging specifications management support inputs. The benefits of the apqp or control plan would be a reduction in the complexity of products quality planning for the customers and organizations, and a means. How to develop a control plan from a pfmea process fmea. Advanced product quality planning and control plan automotive industry action group aiag on.
Aiag apqp phases are planning, product design, process design. Aiags apqp training class takes you stepbystep through the automakers common requirements and what you need to do to achieve compliance. The control plan helps assure quality is maintained in a process by. The intent of the control plan is to formalize and document the system of control that will be utilized. Your process functions should correlate with the steps listed in the flow diagram and control plan. The control plan should be updated when the process is modified or enhanced. The apqp manual was the first thing that came to mind, then i researched other threads for a cookbook or guidance document or other handson literature but have not found what i. Aiag s apqp training class takes you stepbystep through the automakers common requirements and what you need to do to achieve compliance. Document control fmea software, control plan software. All critical characteristics must be addressed within the corresponding process step. In the case of this control plan, a subgroup of five samples is pulled hourly and checked with a gonogo functional gage. Advanced product quality and control plan secured file cannot be printed the apqp manual provides general guidelines for ensuring the advanced product quality planning is implemented in accordance with the requirements of the customer. I am guessing you are looking for the aiag ppap manual 4th edition forms, so i moved your post here. The results are then plotted on a pchart, which is a percentdefectives spc statistical process control chart.
Control plan basics training qualitytrainingportal. With the experience that has been acquired since 1994, it has become. Control plan special control plan checklist the automotive industry action group aiag has standards for completing this form supplier company name part number revision level part name name and telephone number of the key contact date of the latest control plan updates. The control plan is the same as any other tool, in that to get the most value you must know how to use it properly. A control plan contains all applicable critical and significant characteristics. Cqi a19 readiness checklist for subtier supplier management process version1. In this live sap demo, we show you how the control plan is used to ensure fmea characteristics are being consumed in an inspection plan. The role of the requirements risk assessment rra, design fmea, process fmea, design validation plan, design verification plan and process control plan in the product development process. Control plan template in excel to minimize variation. Aiag and vda release draft of harmonized fmea manual. Production part approval process ppap is a component of advance product quality planning apqp developed by the automotive industry action group aiag includes fmea and control plan both as key tools of apqp and.
Advanced product quality planning and control plan aiag. Core tools ppap fmea msa spc apqp control plan these tools are primarily used in automotive industry but can be applied universally to identify defects at an early stage, sometimes much before actual start of production or service, and to qualify processes before bulk processing and to mitigate risks effectively. The control plan does not replace the information contained in detailed operator instructions. Characteristics, control plan, spc along with ongoing feedback assessment and. Advanced product quality planning and control plans. Understanding and implementing process fmea and control plans 4th edition. I understand that the fmea helps identify what can go wrong with the process that ive improved and leads you through to mitigants. The drop down scales are to be used as written in the aiag manual. Qa assistant studio max features include apqp core tools software, document control, risk priority, corrective actions, action priority, criticality for aiag, automotive, medical devices, aerospace, and consumer products. Inspection plan what exactly is the difference dear sir we need version4 control plan excel format. The saeaiag pfmea guidelines describe two methods of defining process functions.
Understanding aiagvda process fmea and control plans for. Advanced product quality planning and control plan reference manual. Linkages between rra, design fmea, design fmea, process fmea, design verification plan, design verification plan and process control plan. Conformity of production is required to ensure that there are adequate. Of the 23 ford apqp elements, 19 are requirements of the aiag advanced. The intent of a control plan is to create a structured approach for control of process and product elements while focusing the organization on characteristics important to the customer. Discuss aiagvda pfmea transition and implementation plan. This section strengthened the control plan requirements and aligned iatf oem customerspecific requirements into the iatf 16949 standard.
Aiag has developed this checklist as a management tool to help determine their organizations readiness for compliance with the aiag subtier supplier management process cqi19. In making a control plan there are things that you need to remember. Production part approval process ppap is a component of. How does an fmea and control plan fit together on a project. It does not give specific instructions on how to arrive at each apqp or control plan. A control plan lists all product and process inspection points required to deliver a defectfree outcome, and is essential for maintaining process control over the long run related. The control plan is an integral part of an overall quality process and is to be utilized as a living document. An important part of a control plan is a reaction plan that clearly specifies what action to take in case an outof control condition occurs. The control plan should also take into account the design fmea and manufacturing process fmea outputs. Pdf application off control plan ppap tool in automotive. Application off control plan ppap tool in automotive industry production article pdf available in quality access to success 146 october 20 with 16,512 reads how we measure reads. Advanced product quality planning and control plan apqp. Sep 27, 2017 it is most effective when incorporated into a larger quality plan.
Control plan describes a producers quality planning actions for a specific product or process. Cqia19 readiness checklist for subtier supplier management. This manual provides guidelines designed to produce a product quality plan, which will support the development of a product or service that will satisfy the customer see section 1. Aiag ppap manual 4th edition forms including control plan.