Download this Excel control plan template and update the header information to suit your business. Also see this plan loaded into Monday.com, an online collaboration tool that brings several advantages over Excel.
Key inputs include the PFMEA and a list of critical-to-quality (CTQ) requirements.
Header Block
| Reference Number / Rev | This is for the control plan itself – control plans can change, independent of drawing specifications. It is important to maintain revision control and to ensure that the lates revision is being used everywhere. |
| Revision Date | Revision date for the control plan itself. |
| Part Number | Engineering drawing or part number that contains the relevant specifications. |
| Approval Blocks | At a minimum, engineering and manufacturing responsible parties should sign off on the control plan. This will prevent confusion in the future, should quality issues arise. |
The header information at the top includes the following information –
Process Name / Operation
The first three columns describe the process step, along with any special requirements –
| Ref # | Normally links back to the process step # in the process flow chart. |
| Process Name | Note what is happening during this process step. |
| Safety or CTQ? | Keep any special notations in this column relative to criticality. Safety or critical-to-quality specifications are the top priority in any control plan. |
Specifications and Controls
The Specifications and Controls section includes –
| Specification / Tolerance | Note the engineering specification, as stated on the drawing, along with the tolerance. |
| Evaluation / Measurement | This is the method for measuring or otherwise evaluating the product/process to ensure that the specification is met. |
| Sampling Requirement | How frequently the measurement will take place. Sampling requirements are usually time based (i.e. once per hour) or quantity based (i.e. once per 500 units). |
| Control Method | This column summarizes how the process is controlled, in order to deliver an in-specification result for the given spec. |
Reaction Plan
The reaction plan describes what must happen if an out-of-specification condition is found. This is about containing the situation to ensure that defective product does not reach the customer. The depth of the containment plan depends on the severity of the defect. Example: an out-of-specification CTQ would result in a more thorough containment plan than a non-CTQ.
Related: Control Plan Training PPT and Control Plan Overview