The Control plan is the description of all Product and Process control operations implemented in the production process. It is a living document and shall reflect the manufacturing process and control systems at all times.
Control Plans form a central part of the Supplier's overall process to achieve Kasai UK requirements for Quality, Cost and Delivery.
In accordance with ISO/TS 16949, there are 3 stages of control plan used during the KSPQP phases:
The Prototype Control Plan:
A Prototype Control Plan is a description of the dimensional measurements material and performance tests that will occur during manufacture of the prototype part.
The Pre-Launch Control plan:
A Pre-Launch Control Plan is a description of the product/ process controls, dimensional measurements, material and performance tests that occur after prototype and before full production.
The Pre-Launch control plan covers the ramp-up period and should include additional product/ process controls to be implemented until the production process is validated e.g. reinforced controls, firewalls, containment etc.
The Production Control plan:
A Production Control Plan is a description of the product/ process controls, dimensional measurements, material and performance tests that occur during mass production.
The production control plan is a logical evolution of the pre-production control plan.
The production control plan shall not be implemented until the exit criteria of ramp-up are achieved.
Minimum Content Requirement
The Control plan shall include:
Identification of all Special Characteristics and Key Features, with suitable control methods and appropriate check frequency.
Identification of process characteristics.
Note: In some processes one process characteristic may affect several product characteristics. e.g. temperature, pressure, time, etc. for injection moulding process. Temperature, current, voltage, pressure, etc. for welding process
Identification of all other features to be checked according to contracted requirements.
The production and process control operations mentioned in the Process flow chart, including rework and repair, storage, "cleanliness" operations if applicable,
The calibration/ maintenance of all control means and the check of the error proofing (Poka-Yoke) devices
Details of reaction plans
The Special Characteristics and Key Features Diagram shall accompany the Control Plan.
The supplier must ensure consistency throughout all documentation (e.g.: Control plan, Process Flow Chart , Special Characteristic and Key Features Diagram, Inspection Report, FMEA) for:
- operation step numbering
- product characteristics identification
Document Description
Item
Completion Instructions
Prototype
Check (tick) this box if this is a Prototype Control Plan
Pre-Production / Pre-Launch
Check (tick) this box if this is a Pre-Launch Control Plan
Production
Check (tick) this box if this is a Production Control Plan
Safe Launch
Check (tick) this box if this is a Safe Launch Control Plan
Project
Kasai UK Vehicle project for which the part is being developed / manufactured.
Document Reference No./ Version
The Suppliers reference no. and version no. for the document.
Document Revision Date
The date of the latest revision of the document.
Document Origin Date
The date when the document was first issued.
Supplier Name
Supplier Company name.
Supplier Plant
Location at which the product will be produced.
Note: If the site supplying off-tool parts for a trial build is different to that supplying off-process parts for a later trial, this should be discussed with Kasai UK and should be reflected in all project management documentation.
Supplier Code
Unique code to each supplier, issued by Kasai UK Purchasing Dept.
Author
The name of the person who created / revised the document.
E-mail
The E-mail address of the person who created / revised the document.
Tel
The telephone number of the person who created / revised the document.
Part Name
The part name or description as identified on the product drawing.
Part No. & Issue Level:
As issued by Kasai UK design department.
Design Note No.
The latest design note number that applies to the product being developed / manufactured.
Supplier Approval
The name and signature of the person approving the Control Plan.
Date
The Control Plan approval date.
Dept
The department in which the above signatory works.
Date
The date of the Kasai UK acknowledgement.
Process No and Process description
The process step number and description taken from the Process Flow Chart.
Machine, Device, Jig, Tools for Mfg
The name of the processing equipment including any identification reference.
Characteristics
No
Characteristic Number as identified in the Special Characteristics and Key Features Diagram
Product
Product Characteristics are the features or properties of a part, component or assembly that are described on engineering documents e.g. drawings, specifications or other engineering information.
Process
Process characteristics are manufacturing process parameters that have an effect on product characteristics.
These parameters must be identified and controlled to ensure product conformity and minimize product variation.
Characteristic Class according to the Special Characteristics and Key Features Diagram.
Key Features Identification:
The Supplier's own identification symbol should be used unless otherwise specified by Kasai UK.
Specification / Tolerance
Specifications/ tolerances may be obtained from various engineering documents, such as, but not limited to, drawings, design reviews, material standard, computer-aided design data, manufacturing, and/ or assembly requirements.
Methods
Evaluation / measurement technique
The measuring system that will be used to confirm the specification or tolerance
This system includes gauges, fixtures, tools, and/ or test equipment required to measure the part/ process/ manufacturing equipment.
Sample Size & Freq’cy
For each activity, the amount of product to be sampled and the frequency the activity will be carried out.
Control Method
This column contains a brief description or reference for how the result of the evaluation and measurement will be controlled.
Maintenance
Any maintenance and calibration activities of equipment, gauges, tools and dies that take place as part of the normal process (e.g. TPM activities). If the supplier has a maintenance activity standard, the standard number should be specified.
Poke Yoke
Describes any error proofing activities incorporated into the process.
Reaction Plan
Countermeasure Action Plan of the Supplier.
For rules related to document submission, refer to the Submission Rules page.
