A process control plan is a document that defines and controls the methods of ensuring consistent production processes. The basis of a control plan is a chart consisting of specific elements that describe a process or action and measurable attributes.
The Format Of A Process Control Plan
The chart headers, seen below, typically follow this format:
- Process No. – This is an identifier for the process step
- Process Name – A description of the process or operation
- Machine/Device/Jig/Tool – Identifies what is used to process the part
- Characteristics – Identifies the steps within the process and the process description
- Class – Importance classification, critical, major or minor or whatever classification you assign to each class
- Process Spec / Tolerance – Indicates the specification and tolerance the process needs to meet
- Evaluation Measurement Technique – Stipulates what is used to measure the process output or dimension
- Sample – Stipulates the sample size and frequency
- Control Method – Identifies how the process is controlled
- Reaction Plan – If the process is found to be out of specification, what actions are taken
One benefit of creating and implementing a process control plan is to improve production output.
It identifies the source of potential process variation and puts controls in place to monitor the process and generally focuses on the most critical characteristics of the job so that the business can reduce scrap rates, eliminate reworking products, and prevent defective items reaching the customer.
By achieving all these benefits, the overall manufacturing efficiency is improved within the factory which ultimately means that you, as a buyer, will get better quality and faster delivery.
Here at Sofeast, we commonly implement this type of plan for our clients who we assist with quality assurance consulting.