How to read a control plan poster

A control plan is the document that says, for each process step, which product and process characteristics are controlled, to what specification, with which gauge, how many and how often, and what to do when a result is out. It links the process flow, the PFMEA and the work at the station. This poster explains each column in a line, so operators, inspectors and team leaders can read their own control plan and follow its reaction plan.

Download the poster

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Download PNG (300 dpi)2550 x 3300 px, prints at 8.5 x 11 in · 460 KB · no form

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Control plan poster — 24 x 36 in18 x 24 inA2A3LetterA4PNG 300 dpi

The words on the poster

Read the control plan

What is checked, how, how often, and what to do when it fails.

Process step Which operation. Matches the flow chart and the FMEA.
Characteristic The feature to control: a diameter, a torque, a temperature.
Special characteristic Safety, regulation, function.
Specification The target and the tolerance.
Method The gauge or technique used to check it.
Sample and frequency How many parts, how often.
Control method How it is held: SPC chart, check sheet, error-proofing.
Reaction plan What to do when it is out: stop, contain, adjust, tell.

Out of spec? Follow the reaction plan first. Then tell your team leader.

Columns after the AIAG APQP and Control Plan manual. Your plan's layout may differ.

On the floor

How to use it

Putting the How to read a control plan poster to work

1
Post it at stations where operators record checks from the control plan.
2
Use it in induction for inspectors and team leaders.
3
Check that each station's check sheet matches its control plan line by line.
4
Pair it with the free control plan, PFMEA and out-of-control action plan templates.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.