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Homepage > training offer > Closed training > Control plans in accordance with the AIAG standard ed. 1 (2024) – creation and development in conjunction with core tools
Control plans in accordance with the AIAG standard ed. 1 (2024) – creation and development in conjunction with core tools

Control plans in accordance with the AIAG standard ed. 1 (2024) – creation and development in conjunction with core tools

The training is largely an extensive workshop, during which we create control plans in accordance with the requirements of the AIAG (ed. 1) and the requirements of IATF 16949. Participants will learn how to create control plans in accordance with an extensive network of links with other core tools. An important point of the training is to know the relationship between the control plan and PFD, FMEA, MSA, SPC, AQL and special characteristics.  After the training, participants will receive a model control plan built during the classes and editable forms.

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IN-COMPANY TRAINING

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TRAINING PROGRAM

For in-company training, the proposed program is a preliminary suggestion and can be freely adapted to the individual needs of the company.

The following program is indicative (the division into days is arbitrary) and the trainer adapts the course of the training to the specific characteristics of the group. Individual topics may be discussed at a different time or in a different form than indicated in the plan.

Module 1

CONTENT:

  • Requirements of norms and standards in the field of process control planning (ISO 9001, IATF 16969, AS13004, AS9145).
  • AIAG guidance on control plans-Control Plan manual ed. 1 (2024).
  • Expected tasks of the control plan.
  • Links PFD, PFMEA and CP.
  • Management of PTC characteristics.
  • Supporting control plans with software-usage policies.
  • Confidentiality of control plans-organization-client relationships (including “black-box” processes).
  • Interdependent processes, modifications and repairs and control plans.

EXERCISES:

Analysis of information passing PFD-PFMEA-CP-workshops.

Module 2

CONTENT:

  • Control plan elements-an overview of each column of a typical form.
  • Types of CP and its tasks for different phases of development, including Safe Launch (new).
  • Custom and off-road forms-overview.
  • Distinguishing product and process characteristics in production and non-production processes (e.g. control phases and logistics).
  • Error-proofing and mistake-proofing in control plans.

EXERCISES:

Creating a control plan system header-a case study.

Defining product and process characteristics.

Module 3

CONTENT:

  • Elements binding the PFD to the control plan.
  • Principles of compliance with PFD.
  • Flow of process phases and characteristics from PFD to control plan.

EXERCISES:

Create an example PFD as input to CP.

Module 4

CONTENT:

  • Key elements of the PFMEA linked to the control plan.
  • Principles of compliance of CP with PFMEA.
  • The role of errors (FM) and causes (FC) in PFMEA in the formation of CP.
  • Switch from error checking (FM) and cause checking (FC) to CP records.
  • Use QFD and DOE to build PFMEA and CP.

EXERCISES:

Defining process characteristics based on PFMEA.

Defining product characteristics based on PFMEA.

Create an outline of a control method based on PFMEA.

Module 5

CONTENT:

  • Determination of sample sizes in control plans based on statistics.
  • SPC as part of the process control methodology.
  • Rules for compliance of the control plan with the SPC.
  • Capability and stability test in the context of control frequency in CP.
  • Determining the frequency of checks in the CP based on knowledge of the stability of the process.
  • Rules for entering SPC tools as elements of the control plan.
  • Sample size design based on AQL.

EXERCISES:

Definition of measurement frequency based on SPC results.

Expansion of the control method and Response Plan based on SPC.

Analysis of sample control cards and capability results and translation of the information obtained into the content of the control plan.

Module 6

CONTENT:

  • MSA as a “consequence” of the entries in the control plan.
  • Types of MSA – review of methods for the needs of CP.
  • MSA results and control planning activities (response to %GRR, ndc, kappa and others).
  • Process supervision with 100% visual control according to the new AIAG CP ed manual. 1.

EXERCISES:

Planning of MSA activities based on the control plan-selection of methods.

Analysis of sample MSA analyses and response to the control plan.

Module 7

CONTENT:

  • The place of special characteristics in the control plan.
  • Rules for transferring special characteristics to CP from external documents.
  • Building a list of special features.

EXERCISES:

Definition of designations for special characteristics.

Define rules for a response plan with special characteristics.

Module 8

CONTENT:

  • Individual fields of a typical form for control plans-an overview with examples.
  • Rules for describing duplicate controls.
  • Invoking instructions and other external documents in the inspection plan.
  • Documenting error-proofing and mistake-proofing-practical examples.
  • Description of the “control method”, i.e. the method of monitoring a given characteristic
  • Planning of actions in case of non-compliance with the specification and appointment of persons responsible (new in CP).

EXERCISES:

Analysis of sample Control Plans-search for non-conformities and model entries.

Create control plans based on data from PFD and PFMEA.

Module 9

CONTENT:

  • 100% visual inspection management.
  • Highly automated process and control plans.
  • Control planning for shared processes.
  • The role of LPA and Reversed PFMEA in supervising control plans (new).

Module 10

CONTENT:

  • Analysis of Actual Control plans developed in the company.
  • Create control plans for selected (real) process phases.
  • Prepare guidelines to assess the consistency of the control plan with other quality management system documentation.

ADDITIONAL INFORMATION

We make sure that a large part of the training is occupied by exercises and practical workshops – then it is easier for training participants to remember new information for them.

During this training, the practice is m.in. tasks in the field of:

Design a process flow diagram as the basis of a control plan.
Define product and process characteristics based on PFD and PFMEA.
Analysis of process behavior using statistical methods-planning of required controls.
Define supervisory methods based on FMEA, SPC and MSA.
Selection of MSA methods under a specific control plan.
Create control plans for production and non-production operations.
Evaluation of the correctness of control plans-working with the AIAG checklist.

Quality engineers, technologists, people working in the automotive industry. Persons responsible for creating a control plan, pfmea analysis.

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    Training Specialist – RONAL Polska Sp. z o.o.
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  • Training on quality management and specific customer requirements delivered by PROQUAL Management Institute met our expectations. The trainers present deep theoretical and practical knowledge, skillfully adapting the content to specific needs, which significantly increases the effectiveness of the training. We recommend PROQUAL Management Institute as a reliable partner in raising quality standards in the automotive industry.
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    HR Manager – Merit Poland Sp. z o.o.
  • PROQUAL conducted training for us in SPC and PFMEA, which stood out for the trainer's engagement and knowledge. The material was supported by many interesting industry examples, allowing participants to better understand the issues. We can wholeheartedly recommend working with PROQUAL
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