This document provides training on control plans, which are used to systematically control processes. It discusses key aspects of control plans such as identifying product and process characteristics, establishing specifications and control methods, and defining reaction plans. The objectives are to understand how to develop a control plan and link each step to the process FMEA. A plug assembly control plan example is also provided to demonstrate how to structure the control plan.

1. Control Plan Training

2. Page 2
Control Plans

3. Control Plan
3
Page 3
Control Plans:
• Control the risks identified in the P-FMEA (High RPNs)
• A structured approach to control process and product characteristics
• Focusses on Customer Requirements
• Assure reaction plans are in place in case of out-of-control conditions
• Provide a central document for communication of control methods
• A Control Plan contains following key information:
 Identification of the control factors
 The specifications and tolerances
 The measurement system
 Sample size and frequency
 The control method
 The reaction plan
• Control Plans are living documents, just like FMEA’s

4. Control Plan, Objectives
Objectives of the training:
• To understand the use of a Control Plan
• To learn the steps to develop a Control Plan
• To learn how to link each step in the Control Plan
to the FMEA
4
Page 4

5. Control Plan, Summary
Control Plan, a systemic way to Control a process:
• Define Characteristics per process step:
• Machines, Devices, Jigs and Tools
• Product, Process and Special characteristics
• Define Methods per process step:
• Process and Product Specifications and Tolerances
• Measurement and Inspection techniques
• Sample size and frequency
• Actions that should be taken in case of
Non Conformities
5
Page 5

6. Control Plan, Summary
Control Plan, a systemic way to Control a process:
• Verify if defined steps are followed
• Audit the process by Control Plan on a regular
base
• Update the Control Plan consistently
6
Page 6

7. Benefits
7
Control Plan, Inputs
Page 7
Control Plan, inputs might include following tools:
• FMEA
• Flow Chart (process sequence)
• Lay-out Plan production line
• Sequence Of Events
• Part Number/ Tooling / Tool List
• Assembly Drawing
• Specifications/ Dimensions/ Tolerances
• CTQ List
• Process Map
• Historical OMS

8. A build B build Pilot
Drawing
Issue part approval form
Tool development
FMEA + control plan
1. Conditional approval
2. HVPT approval
3. Part approval
Quality and capacity confirmation
HVPT process approval
Fit / performance
Purchasing SQE QA
Source SQE approval
Issue HF PA
requirements
HF proto part
approval
HF full part
approval
(OT/OP)
MF and LF
part receipt
Inspection OK
– NOK send
CAR’s
VCB approval
SOP
Page 8
Control Plans, Planning

9. A B C D
Part /
Process
Number
Process Name /
Operation Description
Machine Device
Jig. Tools
for Manufacturing No.
Evaluation
Measurement
Technique
Product Process
Product/Process
Specification
tolerance
Special
Characteristics
Class
Size
Control
Method
Freq.
Reaction
Plan
Sample
Methods
Characteristics
Prototype Pre-launch Production
Control Plan Number Key Contact/Phone Date (Original)
Date (Revised)
Part Number/Latest Change Level
Part Number / Description
Plant / Supplier Supplier Code
Core Team
Plant / Supplier Approval Date Customer Eng.'s Approval / Date (if Required)
Customer Quality Approval / Date (if Required)
Other Approval / Date (if Required)
1 2 5 6 7 8 9 10 11 12
3 4
Advanced Product Quality Planning (APQP) Reference Manual, QS-9000
Page 9
Control Plans
Operation Characteristics Methods Reaction
Plan

10. 1. Part/Process Number:
• Usually referenced from the process flow chart, PFMEA or
Tool sheets
2. Process Name/Operation Description:
• Identify the process/operation that best describes the
activity being addressed (e.g. work elements)
• Use verb / noun format
3. Machine, Device, Jig, Tools for Manufacturing:
• Identify the processing equipment required. (e.g..
machine, device, jig power tools, assist arms, conveyors,
etc.)
What is being done?
A Operation
Page 10
Control Plans
LTVL010 8416010, FRAME, 1x 1
PART/
PROCESS
NUMBER
PROCESS NAME/
OPERATION
DESCRIPTION
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.

11. 4. Number:
• Identifies the cross reference number from the applicable
documentation.
7. Special Characteristic:
• key processes (e.g. Delta K, QS)
5. Product Characteristic:
• Distinguishing features and/or attributes
6. Process Characteristic:
• Characteristics of the process
What is Important?
B Characteristics
Page 11
Control Plans
1 1 Appearance Inspect the frame Y
CHARACTERISTICS
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
NO. PRODUCT PROCESS
SPECIAL
CHAR.
CLASS

12. PRODUCT
CHARACTERISTIC
• physical properties of the part
• Identified important customer
characteristics (CTQs and
Delta-K)
Examples: length, width, tensile
strength, torque, weld integrity, color,
alignment, etc.
A description of the state of the
component or vehicle after the
particular operation is completed
PROCESS
CHARACTERISTIC
• identify characteristics, which
when controlled, reduce
variation in product
characteristics
Examples: pressure, temperature,
force, feed rate, RPM (torque), etc.
Related to product characteristics
Characteristics: Identify Product and Process
characteristics for each Control Plan step
Page 12
Control Plans

13. 8. Product/Process Specification:
• Specifications/tolerance for a part or process. (eg. may be
obtained from various engineering documents)
9. Evaluation/Measurement Technique:
• Identifies the measurement system being used to measure
product/process characteristics. (eg. gages, fixtures, test
equipment, blocks, go/no go, etc)
10 / 11. Sample Size/Frequency:
• List sample size and frequency to perform evaluation. (eg. size: 4
pieces / frequency: fifth time per shift)
What is the Means for Controlling?
Methods
Control Plans
Page 13
C
PRODUCT/PROCESS EVALUATION/ SAMPLE
SPECIFICATION/ MEASUREMENT
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works
hop
OMS Inform Trainer
FREQ.
CONTROL
METHOD
METHODS
REACTION
PLAN
SIZE

14. Benefits
1
4
Control Plan,
Sample size and frequency
Page 14
Station:
1-nov-08
2-nov-08
3-nov-08
4-nov-08
5-nov-08
6-nov-08
7-nov-08
8-nov-08
9-nov-08
10-nov-08
Install O-ring Mee-1247 1
C/R into C/C Mee-1248
S/R assy Mee-1250
S/R height Mee-1251
V-coupling assy Mee-1253
Act assy Mee-1255 1
Lever welding Mee-1288 1 2 3 1
Lever welding Mee-1289
Act measurement Mee-1291 2 2 1 3
Engraving Mee-1256 1
Rev & K-ring check Mee-1257
Weld-assy-act Mee-1258
C/C angle check Mee-1259 1 4
V-coupl-lever-act Mee-1260 2
Total NOK 3 2 1247 0 0 7 1 2 0 4
OK 220 450 300 350 455 275 400 430
• Until a process is Capable (Cpk 1.33), 100% Inspection is required
• If process is Capable, define Sample Size and Frequency reflecting acceptable risk
• Use Six Sigma tools and techniques to control the Process
6
5
4
3
2
1
50
45
40
35
30
Sample
Sample
Mean
_
_
X=39.42
UCL=51.01
LCL=27.82
6
5
4
3
2
1
20
1 5
1 0
5
0
Sample
Sample
Range
_
R=6.17
UCL=20.15
LCL=0
Xbar-R Chart of x
Counting Defects
C-Graph of Defects
SPC Chart
Capability Graph

15. PRODUCT/PROCESS EVALUATION/ SAMPLE
SPECIFICATION/ MEASUREMENT
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works
hop
OMS Inform Trainer
FREQ.
CONTROL
METHOD
METHODS
REACTION
PLAN
SIZE
12. Control Method:
• Brief description of how the operation will be controlled
• When selecting the method of control, focus on:
• process control rather than product control
• prevention rather than detection
• targeting nominal rather than specification limits
Examples:
- Check sheets (weld, quality, tool,
material, etc)
- Preventative tooling maintenance
- Variation control charts
- Error/mistake proofing
- SPC charts
Methods
Control Plans, Control Method
C
Page 15

16. 13. Reaction Plan:
• Specifies who to inform to make a decision or what to do when a
process goes out of control
• Written for people closest to the process (e.g. replace a drill)
• Review systemic root cause and update the FMEA
Examples:
- Call supervisor
- 100% Inspection until the process is back in control
- Calibrate equipment
D Reaction Plan
Control Plans, Reaction Plan
Page 16
PRODUCT/PROCESS EVALUATION/ SAMPLE
SPECIFICATION/ MEASUREMENT
TOLERANCE TECHNIQUE
No damage Visual Inspection 1 1/Works
hop
OMS Inform Trainer
FREQ.
CONTROL
METHOD
METHODS
REACTION
PLAN
SIZE

17. Control Plans, Plug Example
Page 17
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.) 1
1 Wytse Zijlstra
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
PL30 Wytse Zijlstra, Stephen McLaughlin N/A
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
Plug assembly 15/10/2016 N/A
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Hyster-Yale Group N/A
PRODUCT/PROCESS EVALUATION/ SAMPLE
SPECIFICATION/ MEASUREMENT
TOLERANCE TECHNIQUE
PL-10 1010; 1 Plug face Code: PA320,
White Bar Grip
Rew ireable 13A
Resilient Plug Top
Select 1 plug face w ith
inside facing operator
Visual Inspection 100% OMS Inform Trainer
PL-10 1345; 1 Cable Grip.
1060; 2 cable screw s
1 Assembly Fit 1x Cable Grip using 2
cable screw s. Screw hand
tight
Y Ensure Cable Grip
screw s go through
back of cable grip
Hand tight 100% OMS Adjust/ re-check
PL-10 Deliver batch of plugs to station 2 Box OMS Inform Trainer
PL-20 6789; 1 Fuse holder 2 Assembly Fit fuse holder Y Check correct location
of the fuse holder
Visual Inspection 100% OMS Adjust/ re-check
PL-20 1011; 1 Live pin 3 Assembly Fit 1 Live pin Y Pin has fuse clamp on
top
Visual Inspection 100% OMS Adjust/ re-check
PL-20 1213; 1 Neutral pin w ith black band on
pin
4 Assembly Fit 1 Neutral pin Y Check if black band on
pin
Visual Inspection 100% OMS Adjust/ re-check
PL-20 1415; 1 Earth pin Assembly Fit 1 Earth pin Check if pins are in
correct position
Visual Inspection 100% OMS Adjust/ re-check
PL-20 1617; 1 fuse 13 Amp
1616; 1 fuse 5 Amp
5 Assembly Fit 1 fuse Y 13 Amp fuse
5 Amp for Euro
Visual Inspection 100% OMS Adjust/ re-check
PL-20 Deliver batch of plugs to station 3 Box Deliver batch of plugs to
station 3
OMS Inform Trainer
PL-30 2022; 3 screw s to connect w ires Screw driver 6 Assembly Fit 1 screw to Neutral pin,
Earth pin and Live pin and
tighten hand tight w ith
screw driver
Y Ensure all screw s are
nipped tight and unable
to undo by hand
Hand tight 100% OMS Adjust/ re-check
PL-30 Deliver batch of of plugs to station 4 OMS Inform Trainer
PL-40 1819; Plug Front 7 Assembly Fit Plug Front Y Ensure all screw s are
tight
Hand tight 100% OMS Adjust/ re-check
PL-40 2013; Wiring diagram 8 Assembly Fit w iring diagram Y Ensure text is readable Visual Inspection 100% OMS Adjust/ re-check
PL-40 Deliver batch of plugs to QA Box OMS Inform Trainer
PART/
PROCESS
NUMBER
PROCESS NAME/
OPERATION
DESCRIPTION FREQ.
CONTROL
METHOD
CHARACTERISTICS METHODS
H-Y
REACTION
PLAN
05/10/2016
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
NO. PRODUCT PROCESS
SPECIAL
CHAR.
CLASS SIZE

18. Control Plans, Next Steps
Page 18
Next Steps to H-Y Suppliers:
1. Know your customers’ expectations - CTQ’s (Critical to Quality
Characteristics)
2. Have a defined and documented production process (SOE)
3. Follow 5S Principles
4. Employ a formal training system
5. Involve the people on the shop floor
6. Audit the production process constantly
7. Manage supplied parts and control supplier performance
8. Measure/monitor key quality performance indicators
9. Use an effective Corrective & Preventative Action Process
FMEA and Control Plans are mandatory for PPAP
submission level 3.

19. Control Plans, Next Steps
Page 19

20. Quality Focus Day Workshop
Page 20
List of acronyms:
CTQ: Critical To Quality, a characteristic judged to be important to the fit and function of a component or assembly as well
as customer satisfaction
FMEA: Failure Mode and Effect Analysis
ICAM: Interactive Corrective Action Management
OMS: Operational Method Sheet
Off Tool: (Production Tooling) - When a part is said to be “Off Tool” it is required that the part be manufactured using the
exact tooling which will be used for long-term production. This does NOT mean the parts were manufactured from tooling
that is “like” or “similar” to the intended production tooling.
Off Process:(Production Process) – When a part is said to be “Off Process” it is required that the part be manufactured and
tested using the exact process that will be used for long-term production. This does NOT mean the parts were
manufactured using a “like” or “similar” or less than 100% completed process.
P.A.: Part Approval process to determine if part characteristics and specifications are understood and met by the supplier.
PCR: Process Change Request
PFD: Process Flow Diagram
SQM: Supplier Quality Manual
QFD: Quality Function Deployment
QS-9000, PPAP: Product Part Approval Process
QS-9000, APQP: Advanced Project Quality Plan