Training Agenda: AIAG Control Plan
Duration: 1 Day (8 Hours)
Audience: Engineers, Quality professionals, Manufacturing managers, Process engineers, and anyone involved in process control and quality management in automotive or manufacturing industries.
Registration & Welcome
- Attendees sign in.
- Introduction to the training objectives: Understanding and implementing Control Plans as per AIAG guidelines.
- Overview of the importance of Control Plans in maintaining process consistency and product quality.
Introduction to AIAG Control Plan
- Definition of a Control Plan: What it is and why it’s crucial in the manufacturing process.
- The role of Control Plans in Advanced Product Quality Planning (APQP) and their link to Process Flow Diagrams (PFD) and FMEA.
- Types of Control Plans: Prototype, Pre-launch, and Production Control Plans.
Control Plan Structure and Key Elements
- Detailed breakdown of the AIAG Control Plan template:
- Product/Process Identification (Part number, process name, and key process steps).
- Process Characteristics (Key process parameters and controls).
- Product Characteristics (Critical product features and specifications).
- Control Methods (Process monitoring and control methods).
- Reaction Plans (Actions taken when process parameters deviate).
- Activity: Participants review and discuss sample Control Plans to identify key sections and the importance of each element.
Morning Break
Linking FMEA and Control Plan
- How FMEA drives the Control Plan:
- Identifying critical failure modes and risks.
- Ensuring high-risk failure modes are controlled through the Control Plan.
- Severity, Occurrence, and Detection from FMEA to Control Plan controls.
- Activity: Review a sample Process FMEA and develop a preliminary Control Plan based on the risk priorities identified.
Control Methods and Monitoring Techniques
- Discussion of effective control methods to manage product and process characteristics:
- Statistical Process Control (SPC), sampling, inspection methods, automated control.
- Determining control limits, tolerances, and verification methods.
- Activity: Identify appropriate control methods for sample process characteristics.
Lunch Break
Reaction Plans – What to Do When Things Go Wrong
- Definition and importance of a Reaction Plan.
- How to develop effective reaction plans for when the process goes out of control.
- Escalation procedures, corrective actions, and continuous improvement.
- Activity: Develop a Reaction Plan for a sample process failure mode, focusing on immediate containment and long-term corrective actions.
Developing a Control Plan – Hands-On Workshop
- Group Activity: Participants are divided into small groups to create a Control Plan based on a provided case study.
- Teams work through all key elements of a Control Plan.
- Each group will identify product and process characteristics, determine control methods, and create reaction plans.
- Instructor guidance on how to effectively complete the Control Plan, addressing common challenges and best practices.
Afternoon Break
Review and Discussion of Group Control Plans
- Groups present their Control Plans to the class.
- Open discussion on the effectiveness of the Control Plans, potential improvements, and alignment with AIAG standards.
- Peer and instructor feedback on the content, structure, and practical application of each Control Plan.
Best Practices for Maintaining and Updating Control Plans
- Continuous improvement of Control Plans: How and when to update the Control Plan.
- Reviewing Control Plans based on process changes, new risks, and feedback from production.
- Integration with APQP, PPAP (Production Part Approval Process), and continuous improvement initiatives.
- Practical tips for maintaining accuracy and ensuring the Control Plan remains a “living” document.
Wrap-Up, Q&A, and Certificates
- Summary of key takeaways from the training.
- Open floor for questions and clarification.
- Distribution of certificates