AiroQue / Services / Example Control Plans
Examples
Two Control Plans that look nothing alike
Both are Control Plans. One controls a manufacturing process step by step; the other controls a part that passes through the building without being manufactured in it. The format follows the job, not a house template.
About these examples
These are illustrative documents prepared by AiroQue to show structure, depth and tone. All part numbers, drawing numbers, customer and site names, tool and fixture identifiers, internal specification and procedure numbers, and nonconformance reference numbers have been removed or replaced with bracketed placeholders. Process values are representative and are not taken from any released document. Nothing on this page identifies a customer, a program or a part.
A Production process control
Example A — process Control Plan for an assembled, bonded and tested product
Operation-by-operation control of a manufacturing process, with product and process characteristics separated, key characteristics flagged, and a specific reaction written for every row.
Twelve representative operations shown. Scroll the table horizontally to see all twelve columns.
| Op | Process step | Machine / device / jig / tools | Cell | Product characteristic (KPO) | Process characteristic (KPI) | Requirement | Evaluation / measurement technique | Sample size | Frequency | Control method | Reaction plan |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | Stage work order — verify work order, drawing and current work instruction at the station | Work order, current work instruction, traveler | CELL-1 Staging | Correct documentation and configuration at the station | Current-revision instruction present; work order matches part | Work order, drawing and instruction all at current revision | Review work order and instruction; confirm revision against document control | 100% | Each work order | Initial on traveler before work begins | Stop. Do not begin work. Obtain current revision from document control; notify supervisor; confirm no work was performed to a superseded revision. |
| 10 | Issue parts — issue all required parts per kit list with traceability | Kit list, pick list, ERP system | CELL-1 Staging | Correct parts issued with full traceability | All parts issued per kit list; lot traceability recorded | Correct parts and quantities; traceability recorded per procedure | Verify physical parts against kit list; confirm lot and batch records | 100% | Each work order | ERP transaction and pick list complete before release to assembly | Stop. Quarantine kit. Reconcile against kit list, correct the issuance and record the discrepancy per the nonconformance procedure. |
| 20 | Marking — mark component per drawing note | Marking equipment, marking fixture [FIXTURE ID] | CELL-2 Assembly | Marking content, location and legibility | Marking applied with correct fixture setup | Content, location and depth per drawing | Visual verification against drawing, with magnification where required | 100% | Each assembly | Post-marking verification of content and location before next operation | Stop. Segregate the unit and do not proceed. Evaluate for rework per procedure; verify fixture setup and re-verify the next three units. |
| 30 | Cut and strip cable to length | Approved cutting tool, calibrated strippers, measuring tool | CELL-2 Assembly | Cut length; strip length; strand integrity | Tool set to correct length; no nicked or broken strands | Lengths per drawing; no strand damage permitted | Measure length; inspect stripped ends under magnification | 100% | Each assembly | Length measurement and strand inspection recorded | Stop. Scrap the affected piece — rework not permitted. Re-set the tool and verify the next three pieces before resuming. |
| 40 | Contact assembly — crimp contact to conductor | Calibrated crimp tool [TOOL ID], go/no-go gauge | CELL-2 Assembly | Crimp quality and retention (KPC) | Correct tool and die; crimp within specification | Per applicable crimp specification | Visual crimp inspection; pull test per specification | 100% visual; pull test per specification | Each assembly; pull test each lot | Crimp inspection and pull-test results recorded against serial | Stop production. Quarantine every unit produced since the last passing pull test. Verify tool calibration and die; disposition affected units; raise a nonconformance. |
| 50 | Mix casting compound | Calibrated scale, two-part compound | CELL-2 Assembly | Mix ratio, material identity and pot life | Ratio and mix time per manufacturer's data sheet; material within shelf life | Ratio, mix time and cure per manufacturer's data sheet | Verify lot and expiry; weigh on calibrated scale; record batch | 100% | Each mix | Batch record capturing lot, expiry, ratio and mix time | Discard the mix. Quarantine any unit assembled with suspect material. Verify scale calibration, re-mix and record. |
| 60 | Assemble connector bodies to cable | Calibrated torque wrench, assembly fixture | CELL-2 Assembly | Assembly sequence, orientation and torque | Torque applied with calibrated wrench in specified sequence | Torque value and sequence per drawing | Verify sequence and orientation; apply and record torque | 100% | Each assembly | Torque value recorded against assembly serial number | Stop. Segregate the unit. Verify wrench calibration, evaluate the joint for damage and disposition per the nonconformance procedure. |
| 70 | Verify pin depth | Calibrated pin depth gauge | CELL-3 Inspection | Pin depth (KPC) | Gauge within calibration; part seated correctly for measurement | Depth within drawing tolerance | Measure with calibrated gauge and record the actual value | 100% | Each assembly | Actual reading recorded; KPC results retained per contract | Stop. Quarantine the unit and all units since the last conforming reading. Notify quality engineering, raise a nonconformance and notify the customer where the contract requires it. |
| 90 | Cure assembly | Calibrated oven with recording thermocouple | CELL-2 Assembly | Cure temperature and duration | Set point verified; recorder trace continuous for the full cycle | Temperature and time per applicable process specification | Verify set point; monitor recorder trace; retain chart with the batch record | 100% of batches | Each batch | Recorder trace retained with the batch record | Stop. Quarantine the batch. Evaluate the excursion against the specification; disposition by engineering; do not release without evaluation. |
| 120 | Electrical and leak verification | Calibrated dielectric tester, insulation resistance tester, low-resistance ohmmeter, leak test fixture | CELL-3 Inspection | Dielectric withstand, insulation resistance, conductor resistance, leakage (KPC) | Test equipment within calibration; values applied per specification | Test values and limits per applicable test specification | Perform each test at the specified value and record the result | 100% | Each assembly | Test results recorded against serial number and retained | Stop. Quarantine the unit; do not retest without engineering approval. Raise a nonconformance and contain units tested since the last calibration verification. |
| 140 | Final visual inspection | Magnification and controlled lighting | CELL-3 Inspection | Workmanship, marking legibility, cleanliness and FOD | Inspection performed under specified lighting and magnification | No damage, contamination or illegible marking; per workmanship standard | Visual inspection against the workmanship standard | 100% | Each assembly | Inspection stamp and record applied before release to stock | Stop. Segregate the unit, disposition per the nonconformance procedure and assess whether the condition affects the remainder of the lot. |
| 150 | Route to stores | Completed documentation package | CELL-1 Staging | Documentation complete; quantity reconciled | All records present, legible and signed | Complete documentation package per procedure | Final review of traveler, inspection records and test records | 100% | Each lot | Documentation package verified before stock receipt | Hold the lot in quarantine until documentation is complete. Do not receive into stock with missing or illegible records. |
What this format is for
Parts manufactured in-house where risk lives in the process: tool settings, cure cycles, crimp quality, torque, test values. The plan follows the routing so it can be read alongside the traveller.
Why the reaction column is long
Each reaction names stop authority, containment boundary, disposition path and what has to be verified before restart. That is what makes the difference between a nonconformance and an escape.
Tailoring applied here
Product and process characteristics in separate columns, cell identification included, key characteristics flagged in the characteristic text, and sample size and frequency split — all because that is what this reviewer expects.
B Pass-through part control
Example B — pass-through part quality Control Plan
For product received, stocked and shipped without internal manufacturing. There are no operations to control, so the plan is organized by known failure condition and by inspection point — receiving, source, stock and shipping.
Twelve representative conditions shown. Scroll horizontally for the full set of columns.
| Ref | Failure mode / nonconformance | Requirement | Inspection point(s) | Immediate action | Containment | Escalation / notification | Read-across impact | Prevention / future checks | Status |
|---|---|---|---|---|---|---|---|---|---|
| QA-01 | Incorrect or missing port plugs | Both ports plugged with the specified plug type per drawing note | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify plug type and presence | Add plug type and presence verification to receiving and shipping checklists | Open |
| QA-02 | Incorrect fastener hardware installed | Hardware type per drawing; only the fasteners identified on the drawing receive the alternate hardware | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify correct hardware at each location | Update receiving and shipping checklists with a hardware verification step | Open |
| QA-03 | Bent or non-flush nut plates | Nut plates flush to the housing with no deformation, per drawing | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Do not install. | Quarantine the affected lot. 100% visually inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — inspect nut plate condition | Add a nut plate condition check to the incoming inspection instruction | Open |
| QA-04 | Missing protective plugs in test ports | Protective plugs installed in all test ports per drawing note | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Install correct plugs only under an approved disposition. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify protective plugs present | Add a port protection verification step at receiving and prior to shipment | Open |
| QA-05 | Missing fire shield | Fire shield installed per drawing — safety-related feature | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Do not install. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. Treat as safety-related. | All read-across part numbers — verify fire shield presence and attachment | Add mandatory presence and attachment verification at receipt and shipment | Open |
| QA-06 | Damaged fastener heads or fitting flats | No visual damage permitted on fastener heads or fitting flats | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% visually inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — inspect exposed hardware | Add a visual inspection of all exposed fasteners and fittings to the receiving instruction | Open |
| QA-07 | Incomplete or illegible marking | All marking content, location and legibility per the drawing marking note | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify complete and legible marking | Add verification of marking content and legibility to the incoming inspection instruction | Open |
| QA-08 | Missing fluid-type identification tag | Identification tag attached per the drawing and packaging requirement | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify tag present and correct | Add tag verification to the receiving and shipping checklists | Open |
| QA-09 | Coating touch-up exceeds the allowable area | Touch-up limited to the area permitted by the applicable coating specification | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. | Quarantine the affected lot. 100% visually inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — assess coating condition | Add a visual assessment of touch-up extent against the specification limit | Open |
| QA-10 | Uninstalled components not boxed and attached | Uninstalled components boxed and attached to the unit per the packaging requirement | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Locate the loose components before any movement. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify component presence and attachment | Source inspection to verify presence and attachment before release | Open |
| QA-11 | Specified feature not counterbored or countersunk | Counterbore/countersink present where specified on the drawing | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Do not install. | Quarantine the affected lot. 100% dimensionally inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. | All read-across part numbers — verify the specified feature | Add dimensional verification of the specified feature at receipt | Open |
| QA-12 | FOD found in air passages | All parts free of foreign object debris per the applicable FOD control requirement | Receiving, source, stock, shipping | Stop. Quarantine the unit; do not ship, install or move to stock. Do not blow out or clean before evaluation. | Quarantine the affected lot. 100% inspect stock and in-transit units for the same condition. | Notify lead/supervisor and quality engineering. Escalate to the supplier where the condition originates upstream. Treat as safety-related. | All read-across part numbers — inspect all passages and openings | Add FOD inspection of all air passages at receipt and prior to shipment | Open |
Instructions at the inspection point
A plan like this is used by receiving inspectors and material handlers, so the response rules sit on the document itself:
- Stop immediately on discovering any listed condition. Do not continue processing or ship the unit.
- Quarantine the affected unit and any units of the same lot in stock or in transit.
- Document everything: part number, serial or lot, quantity, location, date, and photographs of the condition.
- Notify the lead or supervisor immediately, and quality engineering for any safety-related condition.
- Contain: inspect 100% of stock and in-transit units for the same condition before releasing any of them.
- Notify the supplier where the condition originated upstream, following the purchasing and supplier quality process.
- Notify the customer where the contract requires notification for the condition or the disposition.
- Root cause and disposition are determined by quality engineering with manufacturing engineering, not at the inspection point.
- Update checklists, instructions and training once a condition recurs; this document is maintained as conditions are added or closed.
Why this one is organized by failure mode
When you do not manufacture the part, you cannot control the process that produced it. What you can control is detection at the points the part passes through, and the response when a known condition appears. Read-across is included because these conditions rarely affect only one part number.
Tailoring applied here
Columns for containment, escalation, read-across impact and status, plus a living-document status field — because this plan is maintained as conditions are added and closed, rather than revised only at engineering change.
C The point
The format is a decision, and it is yours
Column structure
Added, removed, merged or renamed to match the form your reviewer expects to receive.
Classification
Special, key and critical designations applied using your customer's symbols and definitions.
Numbering
Operation and characteristic numbering matched to your router, records and drawing balloons.
Wording
Written for engineers, for the floor, or bilingual — using your plant's names for cells, tools and forms.
Want to see this against your own part?
Send a drawing and a routing under NDA. AiroQue can produce a short sample section of a Control Plan in your customer's format before you commit to the full document.