Manufacturing & Process template
Control Plan Template: Build & Export Free
Lay out how each characteristic is controlled (specs, methods, sample sizes and reactions), then export a print-ready control plan as a PDF, free to start.
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Overview
What is a control plan?
A control plan documents the controls used to keep a process and its product in check: for each process step and characteristic, it sets out the specification, how it's measured, how much and how often, and what to do when something goes out of control. It's the document that turns a proven process into a repeatable one.
A good control plan is a table that leaves nothing to chance. Each product or process characteristic is tied to its specification and tolerance, an evaluation or measurement technique, a sample size and frequency, the control method, and a reaction plan for when a result falls outside limits, with clear ownership. It flows directly from the Process FMEA, which identifies what needs controlling.
Control plans are a core APQP tool in automotive and precision manufacturing, and are typically produced for the prototype, pre-launch and production phases. They sit alongside the FMEA and PPAP but do a distinct job: the FMEA finds and ranks the risks, and the control plan defines the ongoing controls that hold them (more below).
The fields
What to include in a control plan
A control plan that actually controls the process is specific and complete. These are the columns reviewers expect, and all of them are in the template.
Control plan header
The part, the phase (prototype / pre-launch / production), the team, dates and revision.
Process step or operation
The process step or operation each control applies to, in sequence.
Characteristic
The product or process characteristic being controlled, and whether it's special or critical.
Specification and tolerance
The specification, tolerance or requirement the characteristic must meet.
Measurement technique
The evaluation or measurement method and the gauge used to check the characteristic.
Sample size and frequency
How many units are checked and how often: the sampling that makes the control meaningful.
Control method
How the characteristic is controlled: SPC, check sheet, mistake-proofing or another method.
Reaction plan
What to do when a result is out of control (contain, adjust, escalate) so nothing bad ships.
Responsibility
Who is responsible for performing the control and the reaction plan.
FMEA linkage and approval
The link back to the PFMEA the control addresses, and the plan's approvals.
Step by step
How to make a control plan
Four passes take you from a blank template to a control plan that holds the process.
List process steps and characteristics
Lay out the process steps in sequence and the product and process characteristics each one controls, flagging special or critical characteristics.
Define specs and measurement
For each characteristic, add the specification and tolerance, and the measurement technique and gauge used to check it.
Set sampling and control method
Set the sample size and frequency and the control method (SPC, check sheet, mistake-proofing) that keeps the characteristic in check.
Add reaction plans and export
Add the reaction plan and responsibility for each control, link back to the PFMEA, get it approved, and export a print-ready PDF.
Which one
Control plan vs. FMEA
They're companion documents in the same toolkit. One finds and ranks the risks; the other controls them in production.
Control Plan
Documents how each characteristic is controlled in production (spec, measurement, sample size, frequency and reaction plan), the ongoing controls that hold the process.
Use to define the controls that keep the process in check.
FMEA
Identifies how a product or process can fail, rates the risk and drives actions to reduce it: the analysis that says what needs controlling.
Use to find, rank and act on failure risks first.
See the FMEA template →Get it right
Common mistakes to avoid
- Characteristics with no specification or tolerance to control against.
- No measurement technique or sample plan, so the control isn't meaningful.
- A missing reaction plan, so no one knows what to do when a result is out of limits.
- A control plan that isn't linked to the PFMEA that identified the risks.
- Not updating the plan across the prototype, pre-launch and production phases.
- Controls listed on paper that aren't actually performed on the floor.
Questions
Frequently asked
What is a control plan?
A control plan documents the controls used to manage a process and its product: for each characteristic, the specification, the measurement method, the sample size and frequency, the control method and a reaction plan. It turns a proven process into a repeatable, controlled one.
What's the difference between a control plan and an FMEA?
An FMEA identifies how a process can fail and ranks the risks; a control plan defines the ongoing controls that keep those risks in check in production. The FMEA is the analysis; the control plan is the control. A Process FMEA feeds directly into the control plan.
What are the three phases of a control plan?
Prototype (controls during initial builds), pre-launch (enhanced controls before full production), and production (the ongoing controls once in full production). The same characteristics are controlled, but the sampling and methods typically tighten in the earlier phases.
What should a control plan include?
A header with the part and phase, the process steps, the characteristics with their specs and tolerances, the measurement techniques, sample sizes and frequencies, control methods, reaction plans, responsibilities, and the link to the PFMEA. This template includes all of them.
How does a control plan link to the PFMEA?
The Process FMEA identifies the high-risk failure modes, their causes and the controls needed. Those become the characteristics the control plan then controls, each with a spec, a measurement method, a sample plan and a reaction plan. The two are meant to be consistent and are usually reviewed together.
Related templates
Read the guideControl plan: how to control the characteristics that matter
A control plan defines, for every important characteristic, how it is checked and what happens when it drifts. Here’s the structure of a control plan, its phases, and how it connects the FMEA to what actually happens on the line.
Read the guide →Documents that go with a Control Plan
FMEA
Structures failure-mode analysis by documenting functions, potential failure modes, effects, causes, controls, risk evaluation and recommended actions.
Open template →PPAP Submission / Report
Organizes Production Part Approval Process submission information, evidence and references used to demonstrate production readiness against customer requirements.
Open template →Inspection Report
Records inspection characteristics, requirements, measurements, methods, evidence and acceptance results for a part, lot or product.
Open template →Build your Control Plan now
Fill in the fields, apply your brand, and export a clean PDF. Free to start.
Note: This template gives you a structured starting point for a control plan. You remain responsible for the accuracy of the characteristics, specifications, controls and reaction plans, and for meeting your own quality system's and customer's requirements before you release it.