How to Set up Process Control Plan that Works - Part 1
For a company to consistently perform at optimal level, they need to place increased priority to cost reduction and waste elimination in their processes. This, in addition to high level of product quality is necessary for a company to succeed in this ever-competitive business world.
Many manufacturing industries have demonstrated competence at detecting problems and developing corrective actions to correct the problem. But it is one thing to detect problem and solve problem as they arise, yet another thing to sustain the corrective actions or process improvement efforts over a long period of time. When a corrective action is not sustained, the process gradually returns to its initial problematic state, hence, the need of a Process Control Plan.
Process Control Plan helps in monitoring processes and assuring that process improvements efforts are maintained over the life cycle of the part or product. Control Plans can be utilized in any industry to ensure product quality including manufacturing, aerospace and others as they help in maintaining manufacturing efficiency, thereby impacting the company’s bottom line positively.
What is a Process Control Plan?
Process Control Plan is a document that describes the steps such as measurements, inspections, quality checks or monitoring of process parameters needed at every phase of a process with the goal of assuring that the outputs from the process conforms to already determined requirements. The Plan provides operators or inspectors with the necessary information required to ensure that the process produce quality parts. They are living documents and should be updated as the measurement methods and controls are improved throughout the life cycle of the product.
A good process plan should include steps taken if a non-conformance is detected in the course of the process. It should be noted that the Process Control Plan isn’t an alternative to a detailed work instructions, hence does not replace it, it is instead used in conjunction with an inspection sheet or checklist. The Plan only helps in assuring that quality is maintained in a process in the event of employee turnover by establishing a standard for quality inspection and process monitoring.
The Process Control Plan is not just a form to fill out, it is a plan developed by the team to control the process and ensure that the process produces quality parts that meet the customer requirements.
Benefits of a Process Control Plan
Developing and implementing Control Plan has a 3-fold benefits as described below:
- Waste Reduction and/or Elimination: The use of a good Process Control Plans helps reduce or eliminate waste in a process. Businesses today must reduce waste everywhere possible.
- Improvement of Product Quality: The Plan helps to improve product quality by identifying the sources of variation in a process and establishing controls to monitor them.
- Facilitates Focus Important Product Characteristics: Control Plans helps to channel focus on the product characteristics most important to the customer and the business, called critical-to-Quality Characteristics. The essence of this is to see ways to reduce scrap, eliminate costly reworks and prevent defective product from reaching the customer thereby improving the throughput of the process.
Click here for part 2 of this article, outlining the levels and vital steps required for setting up an effective Process Control Plan.
About the Author
Adebayo is a thought leader in continuous process improvement and manufacturing excellence. He is a Certified Six Sigma Master Black Belt (CSSMBB), Digital Manufacturing Professional and Management Systems Lead Auditor (ISO 9001, 45001 & ISO 22000) with strong experience leading various continuous improvement initiative in top manufacturing organizations.
You can reach him here.
