Free control plan template

• A control plan lists each characteristic with its specification, measurement, sample size, frequency, control method and reaction plan.
• It flows from the process flow and PFMEA, so every assessed risk becomes a real, monitored control.
• Plans are issued by phase: prototype, then pre-launch, then production, with controls tuned as capability is proven.
• IATF 16949 clause 8.5.1.1 requires a multidisciplinary control plan, and PPAP lists it as a required element.
• The reaction plan defines containment, adjustment, disposition and escalation, so out of control results get a fast response.

Learn more about compliance and inspections in MapTrack.

• Risk traceability: every characteristic and failure mode from the PFMEA is carried into a real, monitored control with an owner.
• Consistent inspection: operators across shifts and sites follow the same sample size, frequency and method, so results stay comparable.
• Faster reaction: a written reaction plan tells the line exactly what to contain, adjust and escalate when a reading goes out of control.
• Audit readiness: a complete plan shows IATF 16949 and PPAP reviewers that controls exist, are linked to risk and are actually being run.
• Smoother launches: prototype, pre-launch and production columns make the increase in control during ramp-up explicit and reviewable.
• Lower scrap and rework: detecting drift at the planned checkpoint stops nonconforming parts before they reach the next operation or the customer.

• Header block: part number, part name, revision level, supplier and plant, control plan number, phase (prototype, pre-launch or production) and the core team.
• Process number and process name or operation description, matched to the process flow diagram so each step is traceable.
• Machine, device, jig, tool or fixture used at that operation, so the control is tied to the equipment that produces the characteristic.
• Product characteristic and process characteristic for each step, with special or significant characteristics flagged using the customer classification symbol.
• Specification or tolerance for the characteristic, stated with units and limits exactly as the drawing or standard requires.
• Evaluation and measurement technique, including the gauge or method and a reference to the measurement system analysis where one applies.
• Sample size and sampling frequency, stating how many pieces are checked and how often, from every piece to a set interval.
• Control method, naming the SPC chart, error proofing, checklist, work instruction or visual standard used to hold the characteristic.
• Reaction plan, defining the containment, adjustment, disposition and escalation steps to take, and who acts, when a result is out of control.

1. Gather the inputs and assemble the team

   Pull together the drawings, process flow diagram, PFMEA, customer special characteristics and any lessons learned, then assemble the multidisciplinary team of quality, process, manufacturing and tooling so the plan reflects how the line actually runs.

2. List each process step and its characteristics

   Walk the process flow in sequence and, for every operation, record the product and process characteristics that must be controlled, carrying across each significant characteristic and failure mode that the PFMEA identified so nothing assessed as a risk is left unmonitored.

3. Define specification, measurement and sampling

   For each characteristic, capture the specification or tolerance with units, choose the evaluation and measurement technique with the right gauge, confirm the measurement system is capable, and set a sample size and frequency that matches the severity and the stability of the process.

4. Set the control method and the reaction plan

   Decide how each characteristic is held, whether by SPC, error proofing, a checklist or a visual standard, and write a clear reaction plan stating the containment, adjustment, disposition and escalation steps plus the responsible owner for when a reading falls outside the limits.

5. Validate, approve and maintain by phase

   Review the draft against the PFMEA for full coverage, obtain the required approvals, issue the correct prototype, pre-launch or production version, and then update the plan whenever the process, tooling, drawing or a corrective action changes so it stays a living document.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• IATF 16949:2016 clause 8.5.1.1 requires a control plan developed using a multidisciplinary approach, covering prototype, pre-launch and production phases.
• AIAG APQP and Control Plan reference manual defines the standard control plan columns and the prototype, pre-launch and production progression.
• ISO 9001 clause 8.5.1 (Control of production and service provision).
• PPAP (Production Part Approval Process, AIAG) lists the control plan as a required element, and the control plan must trace back to the PFMEA.

• ISO 9001:2026, Quality management systems requirements (ISO catalogue)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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