Control Plan Reviewer Notes
Control Plan
Reviewer Notes
A Control Plan is a summary document that describes the systems and processes used to control product and process
characteristics during manufacturing. It translates the risk analysis performed in the Process FMEA into concrete, actionable
controls — specifying what is measured or checked, how often, using what method, by whom, and what happens if a result is
out of specification. The Control Plan is one of the required elements of a PPAP submission and is used daily on the
production floor, making it one of the most operationally important quality documents in the manufacturing process.
This document summarizes the purpose of the Control Plan, its typical structure, the three phases in which it is used, a
reviewer checklist, common findings during review, and space for formal sign-off.
1. Purpose
The purpose of the Control Plan is to ensure that every characteristic identified as important to product quality — whether a
customer-designated special characteristic or an internally identified critical parameter — has a defined, consistently applied
method of control throughout the manufacturing process. It serves as the bridge between the risk analysis performed in the
PFMEA and the day-to-day activity on the shop floor, and is the document operators, inspectors, and auditors reference to
understand what must be checked and how.
A well-constructed Control Plan reduces reliance on inspection alone by emphasizing prevention-based controls where
possible, and ensures that when a characteristic does go out of specification, there is a predefined reaction plan so operators
are not left deciding in the moment what to do with non-conforming product.
2. Typical Control Plan Structure
Field Description
Part / Process Number Identifies the part number and process step being controlled.
Process Name / Operation
Description of the operation, matching the Process Flow Diagram.
Description
Machine / Device / Jig / Tools Equipment used to perform the operation.
Characteristics (Product &
The specific dimensions, features, or parameters being controlled.
Process)
Special Characteristic
Designation (e.g., critical, significant) per customer/internal system.
Classification
Product/Process Specification &
The requirement the characteristic must meet.
Tolerance
Evaluation / Measurement
The method or gage used to evaluate the characteristic.
Technique
Sample Size and Frequency How many parts are checked and how often.
Control Method How the process is controlled (SPC, error-proofing, checklist, etc.).
Reaction Plan The action taken when a result is out of specification.
3. Control Plan Phases
Control Plans are typically developed and used across three phases of a program. The Prototype phase covers control of
dimensional measurements, materials, and performance testing during prototype build. The Pre-Launch phase applies after
prototype and before full production, when additional controls (increased inspection frequency, additional testing) are often
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Control Plan Reviewer Notes
used because the process is not yet fully proven. The Production phase is the steady-state Control Plan used during full-rate
production, and reflects the process at its most mature and capable state. Reviewers should confirm the correct phase is
clearly identified and that controls appropriately tighten or relax between phases based on demonstrated process capability.
4. Reviewer Checklist
• Every operation on the Process Flow Diagram has a corresponding line on the Control Plan.
• Every special characteristic from the DFMEA/PFMEA is represented with an appropriate control.
• Specification/tolerance values match the current design record.
• Measurement techniques are appropriate for the characteristic and match available gage capability.
• Sample size and frequency are justified by process capability and risk (not arbitrarily chosen).
• Control methods reflect what actually occurs on the floor, verified by direct observation.
• A reaction plan is defined for every characteristic, describing containment and correction steps.
• Control Plan phase (prototype/pre-launch/production) is correctly identified and appropriate.
• Revision level matches the current PFMEA, Process Flow Diagram, and design record.
• Control Plan is approved by the appropriate customer and supplier representatives, if required.
5. Common Findings During Review
Finding Typical Reviewer Action
Control Plan line missing for a Process Flow
Return for completion before approval
Diagram step
Special characteristic not identified on the Reject — cross-reference against DFMEA/PFMEA and
Control Plan correct
Reaction plan says only "notify supervisor" with
Request a specific, actionable reaction plan
no containment step
Sample frequency inconsistent with observed
Request justification or revise frequency
process capability
Control Plan revision does not match current
Return for revision alignment before approval
PFMEA revision
6. Reviewer Sign-Off
Role Name Decision (Approve/Reject) Date
Process Engineer
Quality Engineer
Customer Representative
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