Generate AIAG-format Control Plans linked to PFMEAs with proper inspection methods, frequencies, and reaction plans. Supports Prototype/Pre-launch/Production phases. USE WHEN user says 'control plan', 'CP', 'inspection plan', 'process control', 'sampling frequency', 'reaction plan', or 'special characteristics'. Integrates with PFMEA, AutomotiveManufacturing, and MSA skills.
| Column | Description | Source |
|---|---|---|
| Part/Process Number | Operation step number | Process Flow |
| Process Name/Description | Operation description | Process Flow |
| Machine/Device/Jig/Tool | Equipment used | Process documentation |
| Characteristic Number | Unique ID for characteristic | Sequential |
| Product Characteristic | Part feature being controlled | Drawing, spec |
| Process Characteristic | Process parameter affecting product | PFMEA |
| Special Char Class | CC, SC, or blank | PFMEA/Drawing |
| Product/Process Spec | Tolerance or requirement | Drawing, spec |
| Evaluation/Measurement | Gage/method used | MSA |
| Sample Size | Quantity inspected | Based on risk |
| Sample Frequency | How often inspection occurs | Based on risk |
| Control Method | How results are recorded/used | SPC, checklist, etc. |
| Reaction Plan | Action when out of spec | Defined response |
| Severity | Sample Size | Frequency | Rationale |
|---|---|---|---|
| 9-10 (Safety) | 100% | Every piece | Safety critical - no escape |
| 7-8 (High) | 100% or n≥5 | Per hour or per lot | High customer impact |
| 5-6 (Moderate) | n≥3 | Per shift or per setup | Moderate risk |
| 1-4 (Low) | n≥1 | Per lot or periodic | Low risk |
| Cpk Range | Typical Frequency | Notes |
|---|---|---|
| <1.00 | 100% or very frequent | Process not capable |
| 1.00-1.33 | Every hour or more | Marginal capability |
| 1.33-1.67 | Per shift or setup | Capable |
| >1.67 | Per setup, daily, or lot | Highly capable |
| Term | Meaning | When to Use |
|---|---|---|
| Continuous | 100% inspection | Safety, high risk |
| Per piece | Every part | Critical characteristics |
| Per hour | n pieces every hour | SPC, high-risk |
| Per shift | Start and end of shift | Setup-sensitive |
| Per setup | At setup only | Stable characteristics |
| Per lot | One sample per production lot | Low-risk, stable |
| Daily | Once per day | Periodic verification |
| Weekly | Once per week | Very stable |
| Method | Description | Typical Use |
|---|---|---|
| Visual | Operator observation | Surface defects, presence |
| Go/No-Go Gage | Attribute check | Hole size, thread, profile |
| Caliper/Micrometer | Variable measurement | Dimensions |
| CMM | Coordinate measurement | Complex features |
| Height Gage | Surface plate measurement | Flatness, position |
| Profilometer | Surface finish | Ra, Rz |
| Hardness Tester | Material property | HRC, HRB |
| Torque Wrench | Fastener torque | Assembly |
| Leak Test | Seal integrity | Fluid systems |
| Functional Test | Performance verification | End-of-line |
| Method | Description | When to Use |
|---|---|---|
| Check Sheet | Attribute recording | Visual checks, presence |
| Data Log | Variable data recording | Measurements |
| SPC Chart | Statistical control chart | Critical/significant |
| Traveler | Part-specific record | Traceability |
| Electronic | MES/database entry | High volume |
| None (process control) | Poka-yoke, automated | Error-proofed |
IF [out-of-spec condition] THEN:
1. STOP - Halt production/segregate suspect
2. CONTAIN - Quarantine affected parts
3. NOTIFY - Alert supervisor/quality
4. EVALUATE - Determine root cause and extent
5. CORRECT - Implement fix before restart
6. VERIFY - Confirm correction effective
Dimension Out of Spec:
Visual Defect:
SPC Out of Control:
PFMEA Item → Control Plan Entry
───────────────── ───────────────────
Process Step → Part/Process Number
Function → Characteristic
Failure Mode → What we're preventing
Detection Control → Control Method
S/O/D Ratings → Sample Size/Frequency
Special Char → Special Char Class
For each Control Plan line, verify:
When generating Control Plan content:
# Control Plan
**Part Number**: [P/N]
**Part Name**: [Description]
**Customer**: [Customer Name]
**Control Plan Number**: CP-[DEPT]-[SEQ]
**Phase**: [ ] Prototype [ ] Pre-Launch [X] Production
**Revision**: [Rev] | **Date**: [YYYY-MM-DD]
**PFMEA Reference**: PFMEA-[XXX]
## Operation: [Number] - [Name]
### Characteristic 1: [Description]
| Field | Value |
|-------|-------|
| **Char No.** | [Unique ID] |
| **Product/Process** | Product / Process |
| **Class** | CC / SC / - |
| **Specification** | [Nominal ± Tolerance] |
| **Evaluation Method** | [Gage/Equipment] |
| **Sample Size** | [n] |
| **Sample Frequency** | [When] |
| **Control Method** | [Recording method] |
| **Reaction Plan** | [Reference or inline] |
Control Plan is direct output of PFMEA:
Load: read ~/.claude/skills/Pfmea/SKILL.md
All gages in Control Plan require MSA:
Load: read ~/.claude/skills/Msa/SKILL.md
Work instructions must reflect Control Plan:
Load: read ~/.claude/skills/Automotivemanufacturing/SKILL.md
For detailed guidance:
read ~/.claude/skills/Controlplan/CLAUDE.md
For templates:
read ~/.claude/skills/Controlplan/templates/control-plan-template.md
For control method selection:
read ~/.claude/skills/Controlplan/reference/control-methods.md
For sampling guidelines:
read ~/.claude/skills/Controlplan/reference/sample-frequencies.md