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Out-of-control action plan (OCAP) template
An out-of-control action plan, or OCAP, is a written reaction plan for a control chart. It says what the person at the machine does the moment a point or pattern breaks a control chart rule: check the measurement, contain the parts, find the cause, correct it, prove the process is back in control, and record what happened. This template has the seven-step decision flow with a header for the characteristic, the limits, the owner and who to call, a reaction table that sets out what each common signal usually means and what to do first, and an event log. The Excel version times how long each event stays open, counts signals by rule and by cause, and has a chart check that flags rule breaks in a column of readings. A signal means the process has changed; it does not by itself mean a part is out of specification, so the plan treats the two separately.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Header fields for the characteristic, limits, owner and who to call, above a seven-step flow from signal to release, with yes and no branches for a wrong reading and a cause not found.Seven-step decision flowHeader with limits and ownerReaction table for seven signalsEvent logHours to closeSummary by rule and causeChart check in ExcelWorked example
When to use it
When to use an OCAP
- When you run control charts and operators or inspectors need to know what to do when a point goes out, instead of calling the engineer every time.
- When the same signal keeps coming back and nobody can say what was done the last time.
- When you set up a new chart and want the reaction written down at the same time as the limits.
- When an auditor or a customer asks how you react to out-of-control conditions.
- Not for a chart with no limits yet; collect enough data to set them first.
How to fill it in
- 1
Fill in the header for one chart
Name the characteristic and the process, the chart type, the centre line and control limits, the specification limits, the owner, a backup and who to call. One plan per chart, kept where the chart is.
- 2
Choose one rule set
Pick the rules that mean a signal and write them in the header. Published sets use different run lengths, so choose one and use it on every chart.
- 3
Check the measurement first
When a rule fires, re-measure the part and check the gauge and the plotted value. A wrong reading is a measurement problem, not a process problem.
- 4
Contain and diagnose
Set aside the parts made since the last good point, or slow down, as the reaction table says. Then look at the usual suspects: tool, material, setup, machine, method, measurement, environment and people.
- 5
Correct and verify
Fix the cause that was found. Make and measure a few pieces and plot them. The event is closed when the points are back inside and no rule fires.
- 6
Log it and review the log
Write each event in the log with the rule, the cause, what was held and the time to close. Review the log monthly and raise a corrective action for any cause that repeats.
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a shaft diameter chart on a CNC lathe, with limits at 24.988 and 25.012 mm.
- Seven hourly means in a row land above the centre line at 25.000 mm, though every one is inside the control limits. That is the run rule firing.
- The operator re-measures the last subgroup with a second gauge, gets the same reading and rules out a measurement problem.
- Every reading is inside the specification, so the lathe keeps running with a check every 15 minutes and no parts are held.
- The insert turns out to be 150 parts past its planned life. It is changed, and five pieces are measured and plotted.
- The next subgroups are back around the centre line. The event is logged as tool wear and the tool life limit is lowered.
The signal was caught before any part went out of specification, and the log now shows how often tool wear is the cause.
Common mistakes
Reacting to every point
Adjusting the process after each reading adds variation. Act only when a rule fires, and use the reaction table to decide what to do.
Skipping the measurement check
A drifting gauge produces signals that look like process changes. Re-measure and check the gauge before you stop the line.
Stopping at containment
Setting parts aside protects the customer today. Without a cause and a correction the same signal will return tomorrow.
No named owner or phone number
A plan that says escalate without saying to whom is not a plan. Put a name and a way to reach them on the header, and a time after which to call.
Confusing out of control with out of specification
Control limits come from the process; specification limits come from the drawing. A point can be out of control and inside the specification, and the other way round.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite quality issues are logged as tags, ranked in the QA Matrix and traced to their root cause, and digital instructions and checklists with number limits, required photos and signatures build quality into every task.
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FAQ
Out-of-control action plan (OCAP) template: common questions
An out-of-control action plan (OCAP) is a written reaction plan for a control chart. It lists what to check, how to contain suspect parts, who to call and how to confirm the process is back in control when a point or pattern breaks a control chart rule.
Out of control means the process has changed, shown by a point beyond a control limit or a pattern such as a run on one side of the centre line. Out of specification means a part is outside the drawing limits. A process can be out of control while every part is still in specification, and the plan handles the two differently.
Published rule sets use 7, 8 or 9 points in a row. The exact number matters less than choosing one rule set and using it on every chart, so that everyone reacts in the same way.
Check the measurement: re-measure the part and check the gauge and the plotted value. If the reading is right, contain the parts made since the last good point as the reaction table says, then look for the cause.
A control plan describes how each characteristic of a process is controlled and measured. An OCAP is the reaction plan for one control chart: what to do when that chart gives a signal. A control plan often points to its OCAPs.
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- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- Energy loss matrix templateSeven types of energy loss by six energy sources with a cost in each cell, an action plan and an idle-period shutdown checklist.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Chemical inventory and SDS register templateA register of every chemical on site with its hazard class, safety data sheet and label, and a check that incompatible products are kept apart.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.