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APQP Control Plan Example (Linked to PFMEA, with IATF 16949 Contingency Plan)

This is a worked APQP control plan example you can edit: six lines for a machined and assembled part, each tied to a PFMEA reference, with severity, occurrence and detection so the RPN is calculated for you. It follows the structure of the AIAG Control Plan (prototype, pre-launch and production phases), and the sections below show an IATF 16949 contingency plan and risk assessment example.

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Op	Process step	Characteristic (product or process)	Specification / tolerance	Evaluation / measurement method	Sample size and frequency	Control method	PFMEA S	PFMEA O	PFMEA D	RPN	PFMEA ref	Reaction plan
										72
										81
										42
										140
										36
										40

Highest RPN on the plan

140

Rows at or above your internal threshold need an action in the PFMEA, not just a control plan line.

Control plan lines

This is an example for a fictional machined shaft assembly. Replace every value with your own. Severity 9 or 10 lines should be flagged as special characteristics regardless of RPN. A control plan line is only credible if it matches a PFMEA line, a process flow step and a work instruction.

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We can review a PFMEA and control plan pair and flag lines that do not trace to each other.

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How to use this control plan example

Start from the process flow diagram, one row per process step and characteristic. For each row, copy the failure mode's severity, occurrence and detection from the PFMEA so the two documents cannot drift apart, then write the control method that earns that detection score. Delete the example rows and keep the columns. Export to Excel to paste into your APQP package, or to PDF for the PPAP submission folder. Keep a revision log: IATF 16949 requires the control plan to be reviewed and updated when there is a change, a nonconformance or a customer complaint.

One line per characteristic, not per operation
Special characteristics get a customer symbol and a tighter capability target
Reaction plan must name the action, the owner role and what happens to suspect product
Measurement method must reference a gauge with a known GR&R

How the control plan links to the PFMEA

The PFMEA says what can go wrong and how likely it is. The control plan says how you stop it or catch it. Detection in the PFMEA must be justified by a control that really exists on the control plan: if you scored detection 2 because of an automatic force monitor, the monitor must appear in the control method column with an automatic reject. Under the AIAG and VDA FMEA handbook, Action Priority (High, Medium, Low) has replaced RPN as the preferred prioritisation, so keep severity visible and do not rely on a single RPN cut-off. This worksheet shows RPN for familiarity, but record the AP rating in your PFMEA.

IATF 16949 contingency plan example

Clause 6.1.2.3 asks for contingency plans that cover events such as key equipment failure, interruption from external providers, recurring utility interruption, labor shortage and cyber attack on information systems. A usable plan lists the event, the impact on customer shipments, the immediate action, the backup resource, the owner and how often it is tested. Example: if the press-fit station fails, the plan names the second approved press, the maximum buffer stock in finished goods (for example two shifts), the person who calls the customer, and the requalification steps before shipping resumes. Review the plan at least annually and after any activation.

IATF 16949 risk assessment example

Risk analysis in IATF 16949 appears in clause 6.1.2 (risk and preventive action), in the PFMEA, and in supplier selection. A simple risk register lists the risk, cause, likelihood, impact, existing control, action, owner and due date. Example: single-source bar stock with a 12 week lead time scores high on impact, so the action is to qualify a second mill and hold 4 weeks of safety stock. Keep it short and tie each risk to a process in the turtle diagram so it gets reviewed with the process, not in a separate file nobody opens.

Frequently Asked Questions

What is the difference between a control plan and a PFMEA?

A PFMEA is the risk analysis: it lists failure modes, their effects and causes, and scores them. A control plan is the operational document: it states how each characteristic is checked or controlled, how often, and what to do when the result is out of tolerance. They must reference each other.

Do I need three control plans (prototype, pre-launch, production)?

The AIAG control plan describes three phases, and your customer decides which are required. Many suppliers keep one document and add a phase column, with prototype and pre-launch lines being more inspection-heavy. Production control plans are the ones submitted with PPAP.

Is RPN still used in IATF 16949?

IATF 16949 does not mandate RPN. The 2019 AIAG and VDA FMEA handbook introduced Action Priority, and many customers now expect it. RPN is still common, but a high severity item needs attention even when its RPN is low.

Who must approve the control plan?

It is developed by a cross-functional team, and IATF 16949 requires customer approval where the customer specifies it. Keep signatures or electronic approvals for the team, and make sure operators have access to the released version at the station.

If your PFMEA, control plan and inspection results live in different files and an ERP, Netray can build a private AI layer that checks them against each other on your own servers. We can also run it inside your network.

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