Build to Print Inspection Plan Template
A build-to-print job succeeds or fails on whether the shop measured what the drawing actually controls. This template turns the customer drawing into a one-page plan: each characteristic, how it will be measured, how often, and what to do when something is out.
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Build to Print Inspection Plan Template
Inspection Plan
Company: Acme Precision Machining Part number: BRK-4471-A Revision: C Part name: Mounting bracket, 6061-T6 Customer: Customer A PO / Job: J-24518 Lot quantity: 240 Drawing standard: ASME Y14.5-2018 Sampling basis: c=0 sampling plan Plan date: 2026-10-21 Prepared by: Quality Engineer
Customer Requirements
First article per AS9102. Certificate of conformance and material certs with each shipment. No unauthorized process changes.
Characteristic Plan
| Bubble | Characteristic and zone | Nominal and tolerance | Class | Method and gage | Sample and frequency | Record |
|---|---|---|---|---|---|---|
| 1 | Bore A, zone C3 | 12.000 +0.010 / -0.000 mm | Critical | Air gage, setting ring verified | 5 per hour plus first and last piece | SPC chart |
| 2 | Position of bore A to datums A, B | 0.10 dia at MMC | Critical | CMM program BRK4471 or functional gage | First piece and 1 in 10 | CMM report |
| 3 | Flatness of face B, zone B2 | 0.05 mm | Major | Granite plate and indicator | First piece and 1 in 20 | Check sheet |
| 4 | Overall length | 80.00 +/- 0.15 mm | Minor | Digital caliper | 5 per lot | Check sheet |
| 5 | Thread M6x1-6H, 4 places | Go / no-go | Major | Thread plug gage | 100 percent | Check sheet |
| 6 | Surface finish, bore | Ra 1.6 um max | Major | Profilometer | First piece and 1 per hour | Check sheet |
| 7 | Visual / burrs and edge break | Per drawing note 4 | Minor | Visual with 10x magnifier | 100 percent | Check sheet |
Gage and Equipment List
| Gage ID | Description | Range and resolution | Calibration due | Gage R&R or MSA status |
|---|---|---|---|---|
| AG-014 | Air gage with setting rings | 11.95 to 12.05 mm, 0.001 mm | ||
| CMM-02 | Bridge CMM | 0.0025 mm accuracy | ||
| DC-221 | Digital caliper | 150 mm, 0.01 mm |
Reaction Plan
If a measurement is out of tolerance: stop the operation, quarantine all parts since the last good check, notify quality, and do not adjust the process without recording the change.
If a trend toward a limit is seen (two consecutive points beyond two thirds of the tolerance): inform the supervisor and check tool wear, offsets and coolant temperature.
If the customer approves a deviation, record the deviation number and apply it only to the stated quantity.
Approvals
Starting point for a plan, adapt the characteristic table to the actual drawing balloons. Keep one row per drawing characteristic and list how it is measured, not only the tolerance. Confirm gage resolution is at most one tenth of the tolerance and that gages are within calibration. Where a customer quality clause conflicts with this plan, the customer clause governs. This template is not legal advice.
Draft inspection plans from your ERP and drawings
Optional: we can discuss how a private agent could pre-fill plans from your part, routing and customer requirement data.
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How to use the template
Work from a ballooned drawing. Fill in the header fields, then edit the characteristic table so that every balloon has a row with the exact tolerance, class, method, sample size and record. Add your gage IDs to the equipment list with calibration due dates. Export to PDF or Word and attach it to the router or job traveler. For quoting, the same table shows the estimator where special inspection time is required, such as a CMM program for position or a profilometer for finish.
- Balloon the drawing first, one balloon per requirement.
- Record the zone or sheet location for traceability.
- State the method specifically: the gage ID, not just 'caliper'.
- Define reaction and quarantine rules before the run starts.
Choosing methods and gages
Match the gage to the tolerance and the control. Use a rule of ten: gage resolution should be at most one tenth of the tolerance band. Hole size is best checked with an air gage, bore gage or plug gage; position callouts need a CMM or functional gage; runout needs a rotating fixture or V-blocks with an indicator; thread tolerances need go/no-go gages or thread micrometers. Document any measurement system analysis results, since many customers expect a Gage R&R under 10 percent of tolerance for critical features and require evidence for CMM programs.
Sampling and frequency
Critical characteristics typically get first-piece, in-process and last-piece checks, with control charts if volumes justify it. Major characteristics get first-piece and periodic checks, and minor ones get sample checks at final inspection. The plan can use 100 percent inspection, a c=0 sampling plan, or an AQL plan from ANSI/ASQ Z1.4 when the customer requires it. The sampling basis field makes the rule explicit, so inspectors and auditors read the same instruction. Link any frequency to the capability data you have.
Common mistakes
Plans that copy the tolerance without the method leave inspectors guessing. Plans that list only dimensions miss notes, such as surface treatment, marking, cleanliness and certification requirements. Another frequent error is not updating the plan when the drawing revision changes. Keep the revision in the header and require a review whenever a new revision arrives. Finally, close the loop: results from the plan should flow into your quality system so repeated escapes lead to corrective action.
Frequently Asked Questions
Do I need an inspection plan for every part?
Most quality systems, including AS9100 and ISO 9001, expect documented inspection requirements for each product. A short plan per part number or family is the usual way to meet that expectation and gives inspectors a consistent instruction for each job.
What is the difference between an inspection plan and a control plan?
A control plan, common in automotive APQP, covers the whole process including process parameters, reaction plans and special characteristics across the flow. An inspection plan focuses on product characteristics and how they are verified. Small shops often combine both into one document.
How many characteristics should be on the plan?
Every characteristic on the drawing should be covered, but not at the same frequency. Use classes to scale effort: critical features get frequent checks and charts, minor ones get light sampling. A part with 40 balloons may show only six or eight at high frequency.
Is this an AS9102 first article report?
No. An AS9102 report records actual measured results for a first article. This plan defines how characteristics will be inspected. You can use the plan as the basis for the first article form, which needs measured values for each balloon.
If your drawings, routings and inspection results live in an ERP, Netray can help build a private agent that drafts a plan from the drawing data and pre-fills it for your quality engineer to review.
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