Control Plan

What is the purpose of control plan?

• The purpose of control plan methodology is to aid in the manufacture of quality products according to customer requirements

• To define the organizational structure and responsibilities within the production team

• To establish financial targets and cost reduction strategies for manufacturing processes

• To document employee training programs and certification requirements for operators

Which of the following are requirements for Special Characteristics according to the manual?

• 1. All special characteristics (product and process) must be included in the control plan

• 1. All DFMEA items must be designated as special characteristics

• 1. Special characteristics must be indicated in the “Special Characteristic Classification” column of the control plan

• 1. Customer-designated special characteristic classifications must be used as required

• 1. DFMEA items with a severity rank of 9–10 that flow to PFMEA must be designated as special characteristics

Which of the following are requirements for Pass-Through Characteristics (PTCs) according to the manual?

• 1. Organizations must identify any characteristics that meet the definition of Pass-Through Characteristic

• 1. Organizations must rely solely on supplier certification to control PTCs

• 1. Organizations must have a process to validate the effectiveness of the supplier’s control

• 1. Organizations must document all PTCs and review control methods with the customer

• 1. If receiving inspection based on sampling is used, it must be included in the control plan

Which of the following are requirements for Error-Proofing Confirmation according to the manual?

• 1. Error-proofing devices must be listed on the control plan

• 1. The method and frequency to confirm effectiveness must be included in the control plan

• 1. Error-proofing verification frequency can be based on operator convenience

• 1. Verification frequency must ensure containment since last good check

• 1. Master defect samples must be clearly identified and controlled

Which of the following are requirements for Families of Control Plans according to the manual?

• 1. The organization must list all individual part numbers included in the Family Control Plan

• 1. A separate document may be referenced if there are too many part numbers

• 1. Family control plans can be applied regardless of equipment or process differences

• 1. Family control plans may only be used when parts share the same or equivalent equipment and controls

• 1. Part identification is optional in a Family Control Plan

Which of the following are requirements for Rework and Repair Processes according to the manual?

• 1. The control plan must indicate start and finish of rework using the original process

• 1. A separate control plan is required for alternate rework processing

• 1. Repairs may be performed without customer approval if internally authorized

• 1. Any repair process must have its own control plan

• 1. The organization must ensure traceability of reworked or repaired parts

Which of the following are requirements for Reaction Plan Details according to the manual?

• 1. The reaction plan can define general actions without detailed instructions

• 1. The control plan must include specific actions or reference a document

• 1. The reaction plan only applies to out of specification conditions

• 1. The responsible role must be identified or referenced

• 1. The reaction plan must address out of control and/or out of specification conditions

Which of the following are requirements for 100% Visual Inspection according to the manual?

• 1. The control plan must include periodic verification of the visual inspection

• 1. Verification is optional if operators are trained

• 1. The verification must define who is responsible

• 1. Customer-approved master or boundary samples must be available if not measurable

• 1. Visual inspection does not require validation if used as control method

In a Control Plan, what is the purpose of the “Reaction Plan” section?

• To define the actions to be taken and the responsible person when a process is out of control or out of specification

• To describe the equipment and tools required for the manufacturing process

• To list the product and process characteristics to be monitored

• To define the sample size and frequency of inspections

In a Control Plan, what is the purpose of the “Machine, Device, Jig, Tools for Mfg.” column?

• To identify the equipment and tooling used in each process step

• To define the measurement method for product characteristics

• To list the required operator qualifications

• To describe the control limits for the process