The Process Control Plan, a Tool To Avoid Rework & Scrap [Video]

Have you implemented a process control plan to reduce rework and scrap? In this post I will explain why this tool is really useful, and walk you through how it works in a short video...

Reworking batches of products? You will benefit from a process control plan 

There is a saying in manufacturing that I like: “We don’t have time to do it right the first time, and yet we always have time to do it two times.” Ironic, but true.

How many times has your factory, or one of your suppliers’ factory, had to rework a batch of products for the simple reason that they didn’t pay much attention to it the first time?

The difficulty is, how to plan for a process control system that addresses most opportunities for quality issues, and then how to get everybody in production & quality to comply with that plan?

By setting up and using a process control plan.

What does a process control plan look like?

What does it look like?
The good thing is, it is largely standardized since it is one of the core tools specified by the AIAG (the action group that gathers most North-American and European auto makers) and required by the IATF 16949:2016 standard.

I prepared a short video on this topic where you can see such a plan and its benefits live:

How to develop your own plan?

Usually by following this sequence:

1. List the process steps
2. Based on the customer’s requirements and the needs of downstream processes, list the main potential issues (this is done best by doing a process FMEA)
3. For each issue that represents a relatively high risk, decide on how to control it

What do you think? Do you use process control plans in your operations, and how useful have they proven to be?

Leave a message in the comments below and we’ll be happy to respond.