Control Plans assure a system is in place to control the risks
of the same failure modes as identified in the PFMEA. While Control
Plans can be developed independently of PFMEAs, it is time and
cost-effective to link Control Plans directly to PFMEAs.
primary intent of Control Plans is to create a structured approach
for control of process and product characteristics while focusing
the organization on characteristics important to the customer.
Control Plan does assure well thought-out reaction plans are in
place in case an out-of-control condition occurs and provides a
central vehicle for documentation and communication of control
Special attention is typically given to potential
failures with high RPNs and those characteristics that are critical
to the customer.
A Control Plan deals with the same information
explored in a FMEA plus more. The major additions to the FMEA needed
to develop a Control Plan are:
Identification of the control
The specifications and tolerances.
The control method.
The reaction plan.
Donít let Control Plans become static.
Just like work
instructions, make Control Plans a living document.
As changes in
product or process characteristics, specifications, measurements
systems, sampling, control methods, or the reaction plan are
identified, update the control plan.
Use the revision as a
communication tool to spread the word of the changes to the supply
By making the FMEA a living document, you can be sure that
potentials for failure are continually being eliminated or reduced.