Control Plan Generator
Fill in process characteristics, control methods, and measurement tools in IATF 16949 format to generate an exportable Control Plan table.
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Process Control Items
| Process Step | Char. Type | Spec / Tolerance | Measurement Tool | Sample Size | Frequency | Control Method | Reaction Plan | |
|---|---|---|---|---|---|---|---|---|
In APQP Phase 4 (Product & Process Validation), a formal Control Plan must be established for new products, listing each process step's key product characteristics (KPC), measurement tools, control frequency, and reaction plans — providing complete documentation for quality control in mass production. The Control Plan is a core PPAP submission element and a primary focus of customer audits; it must be fully linked to the FMEA and Process Flow diagram.
Process step: SMT reflow soldering Control item 1: solder joint thickness - Characteristic type: dimension (variable) - Spec: 1.8 ± 0.2 mm (USL=2.0, LSL=1.6) - Measurement tool: laser thickness gauge (0.01 mm resolution) - Frequency: first article per lot + 3 samples every 2 hours - Control method: X̄-R control chart - Reaction plan: out of control limits → stop line & notify engineer → SPC analysis → replace solder paste
FAQ
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Failure Mode & Effect Analysis
FMEA identifies risks; the Control Plan implements the control measures. Both are tightly linked in APQP and must stay consistent.
Open toolPPAP Checklist
The Control Plan is one of the 18 PPAP elements. Use the PPAP checklist to confirm all elements are complete before customer submission.
Open toolGage R&R Study
Measurement tools specified in the Control Plan must first pass an MSA study; gauge %GRR is a prerequisite for Control Plan reliability.
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