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A control plan lists all product and process inspection points required to deliver a defect-free outcome, and is essential for maintaining process control over the long run. See the control plan training PPT for a training file and control plan excel template for a streamlined template.
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.
This Control Plan Training Course provides you with the materials you need to share control plans with with team members, customers, and suppliers (download here). Course Outline. Walk Through Control Plan Elements. An example control plan from a furniture manufacturer is reviewed, using the streamlined control plan template.
PFMEA. PFMEA (Process Failure Mode and Effects Analysis) is a structured approach that assigns quality risk levels to each step in a process – download a PFMEA excel template here. PFMEA is a powerful prevention tool, since it does not wait for defects to occur, but rather anticipates them and implements countermeasures ahead of time.
Product Level CTQ Examples. A cordless drill must deliver 235 inch-pounds of torque to drive a full range of decking screws. A bathroom fan must be 95% reliable after 600 hours of continuous operation. The door panels in a car must align within 2mm of each other at all locations.
PFMEA’s are one of the strongest, prevention-based DMAIC tools. Lastly, the control plan is a key document that fully describes all in-process inspection and control points, and is considered a basic element of the quality system.
Control Plan Effectiveness – Shop floor feedback to Quality/Engineering is a key element in ensuring that control plans are current and effective. monday.com facilitates this very easily with row-level conversations –
A Gage R&R study is a critical step in process improvement projects, and it quantifies three things –. Repeatability – variation from the measurement instrument. Reproducibility – variation from the individuals using the instrument.
DMAIC is a 5-step approach for improving any measurable outcome: Define, Measure, Analyze, Improve, and Control. For related Powerpoint training files see DMAIC Training and Statistics Behind Six Sigma .
There are several good working examples of the DMAIC methodology in these documents. Six Sigma Overview (Statistical Definition) – DMAIC Tools. RACI Chart: Responsible, Accountable, Consulted, Informed. Implementing Six Sigma Quality at Better Body Manufacturing. Control Plan Training – DMAIC Tools. 5-Why Training – DMAIC Tools.