Prozanta Template
Control plan
Systematic quality control with measurement points and reaction plans
Process / Part no.:
Customer:
Rev. date / no.:
Product / Process type
Prepared by
Approved by
Valid from
How to use this template
The control plan defines precisely what is controlled in a process, when, with what, by whom — and what happens if the control shows a deviation. It is the foundation for systematic quality management and a requirement in IATF 16949 and ISO 9001. A control plan is a living document: it is updated on process changes.
P — Product control
- Control of the physical output: dimensions, tolerances, visual inspection
- E.g. diameter 25 mm ± 0.1 mm
C — Process control
- Control of the process input parameters: temperature, pressure, speed
- E.g. melt temperature 185°C ± 5°C
S — System control
- Audit and verification of systems and documentation
- E.g. weekly check of calibration status
Step by step
- List all process steps that can affect product quality — a process flow diagram is a useful input.
- For each step: identify the characteristic that is critical (what can go wrong and what is the tolerance?).
- Choose the measurement method and equipment — state calibration requirements and sample size.
- Set the frequency: how often depends on the process's stability — unstable processes need tighter control.
- Define the reaction plan: what happens specifically if a control shows a deviation? Who is it escalated to?
- Update the control plan when the process changes — an outdated control plan gives false confidence.
Watch out
- Only control what can actually deviate and affect the customer — too many control points create blindness.
- A sample is a compromise: the more critical the characteristic, the larger the sample (or 100% control).
- The reaction plan is just as important as the control itself — without a plan, a deviation leads to panic and arbitrary actions.
Example
Process step: welding. Characteristic: tensile strength ≥ 350 MPa (P-type). Method: tensile test. Sample: n=3 per batch. Frequency: 1/shift. Reaction: stop production, quarantine the latest batch, call the welding technician.
Method: AIAG APQP Control Plan (3rd ed.); used in IATF 16949, ISO 9001 and general quality management. Combine with FMEA for best practice.
Control plan
| # | Process step | Characteristic controlled | Type | Specification / Tolerance | Measurement method / Equipment | Sample size | Frequency | Who controls | Recording | Reaction plan on deviation |
|---|---|---|---|---|---|---|---|---|---|---|
| 1 | P/C/S | |||||||||
| 2 | P/C/S | |||||||||
| 3 | P/C/S | |||||||||
| 4 | P/C/S | |||||||||
| 5 | P/C/S | |||||||||
| 6 | P/C/S | |||||||||
| 7 | P/C/S | |||||||||
| 8 | P/C/S | |||||||||
| 9 | P/C/S | |||||||||
| 10 | P/C/S |
Type: P = Product control, C = Process control, S = System control
Reaction plans — what to do on a deviation
| Control point (from plan) | Deviation type | Immediate action | Long-term correction | Escalate to |
|---|---|---|---|---|