AIAG_Control_Plan_Deep_Understanding.pptx

Control plan presentation

1. AIAG Control Plan - Deep Understanding Detailed Guide with Examples and Layout

2. What is a Control Plan? • A Control Plan is a living document that describes actions required at each phase of a process. • It is used to control characteristics, processes, and ensure quality. • Focused on minimizing variation and defects by providing detailed instructions.

3. AIAG Control Plan Levels 1. **Prototype Control Plan:** • Focuses on dimensions, material, and performance during development. 2. **Pre-Launch Control Plan:** • Temporary document for early production with higher sampling. 3. **Production Control Plan:** • Final plan for stable, mass production to ensure process capability.

4. Structure of a Control Plan Table Typical Columns: • Process Number & Step • Part/Process Characteristics • Product Specification & Tolerance • Measurement Method & Equipment • Sample Size & Frequency • Control Method (SPC, Poka-Yoke) • Reaction Plan

5. Visual Example of a Control Plan Table Example: ┌────────┬───────────────────────┬───────────┬─────────────┬──────────────┬───────────────┐ │ Step # │ Process Description │ Spec/Tol │ Measure │ Sample Freq │ Reaction Plan │ ├────────┼───────────────────────┼───────────┼─────────────┼──────────────┼───────────────┤ │ 1 │ Cutting Length │ ±0.5 mm │ Vernier │ 1/Batch │ Stop & Adjust │ │ 2 │ Hole Drilling │ ±0.2 mm │ CMM │ 1/50 pcs │ Rework Part │ └────────┴───────────────────────┴───────────┴─────────────┴──────────────┴───────────────┘

6. Key Tools Linked to Control Plan • **FMEA (Failure Mode & Effects Analysis):** Identifies risks and controls. • **SPC (Statistical Process Control):** Tracks process stability. • **MSA (Measurement System Analysis):** Validates measurement accuracy. • **PPAP (Production Part Approval Process):** Ensures readiness for mass production.

7. Benefits in Depth • Improves communication between engineering, quality, and production teams. • Standardizes inspection and reaction plans for defects. • Ensures compliance with IATF 16949 and customer requirements. • Reduces variation and improves customer satisfaction.