Production Control Plan Worksheet for PPAP (Excel Export)
The control plan describes how each important product and process characteristic is controlled during production. In PPAP it is submitted with the PFMEA and process flow. This worksheet lays out the standard columns so you can fill it row by row and export it to Excel.
| Op no. | Machine / device | Characteristic | Class | Specification / tolerance | Measurement method | Sample size | Frequency | Control method | Reaction plan | |
|---|---|---|---|---|---|---|---|---|---|---|
The control plan is a living document. Use the prototype, pre-launch or production phase your customer expects and keep it aligned with the PFMEA and process flow.
Want inspection plans compared to your control plan?
Optional review of how ERP inspection plans can be checked against a PPAP control plan.
Optional. The tool and every export work without this. No spam.
How to fill each column
Use the same operation numbers as the process flow and PFMEA. List product characteristics from the drawing and process characteristics such as temperature, pressure or torque. Give each a specification with units, the measurement method including gage type, a sample size and a frequency, and a control method. The reaction plan should say what the operator does next, who is notified and how suspect product is contained. Vague entries like 'inform quality' are a frequent audit finding.
- Link every special characteristic to a control
- State frequency as a number and a unit of time or quantity
- Name the gage so the MSA study can be traced
- Write reaction plans as actions, not intentions
Choosing control methods
Poka-yoke and automatic checks are stronger than visual checks, and SPC suits variable data with enough volume to chart. Go/no-go gages are fast but give attribute data only. First piece approval protects against setup errors but not drift. Choose the method that matches the PFMEA detection rating you claimed, because a control plan that relies on a visual check cannot support a detection score of 2.
Reading the example
The example shows four operations with different control strengths. The bore diameter is a fit and function characteristic charted by SPC with hourly samples. The wash residue is critical, so it is controlled by lot sampling with a hold. The summary counts control points and total samples per cycle, which helps you estimate inspection labour for the run at rate study.
Common mistakes
Typical failures are mismatched operation numbers, specifications copied without units, sample sizes with no basis, and reaction plans that never mention containment. Review the control plan whenever the process, gage or customer requirement changes, and record the revision. If your ERP or MES holds routings and inspection plans, keep the characteristic and operation references identical there.
Frequently Asked Questions
What are the three control plan phases?
The AIAG control plan manual describes prototype, pre-launch and production phases. Prototype covers build and test of prototype parts, pre-launch covers the stage after prototype and before full production, and production is the full-volume control. Mark the phase on the header.
Does a control plan replace work instructions?
No. The control plan summarises what is controlled and how often. Detailed steps, setup values and gage handling belong in work instructions or inspection instructions that the control plan references.
How is sample size decided?
Base it on process capability, risk and customer requirements. Stable capable processes can use smaller or less frequent samples, while new or marginal processes need more. Document the rationale and review it after the initial process study.
Can I export this worksheet?
Yes. Download it as Excel, CSV or PDF using the export buttons and add your company header and revision details in the exported file.
If your inspection plans live in an ERP such as SAP QM or SyteLine, Netray can help check them against your control plan with read-only access.
Related Tools
PFMEA Worksheet with RPN for PPAP
Editable process FMEA table with severity, occurrence, detection and automatic RPN, ready to export to Excel for a PPAP package.
Quality & InspectionPPAP Process Flow Diagram Template
Fill in a header and an operation table that documents the production flow from receiving to shipping, ready to export.
Quality & InspectionSpecial Characteristics Matrix Worksheet
Trace each special characteristic from drawing to PFMEA, control plan, gage and capability study in one editable table.
Quality & InspectionInitial Process Study Cpk Worksheet
Summarise capability for each characteristic from mean, standard deviation and limits, and flag those below the PPAP acceptance target.
More Quality & Inspection tools
See all- PPAP Submission Level Requirements Reference
- PPAP Part Submission Warrant Template
- APQP Timing Plan Worksheet
- IATF 16949 Internal Audit Checklist
- Run at Rate Calculator
- PPAP Dimensional Results Worksheet
- Customer Specific Requirements Matrix Worksheet
- APQP Phase Gate Checklist
- Appearance Approval Report Template