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Controlplan skill

/skills/Controlplan

This skill generates AIAG-format control plans linked to PFMEAs, detailing inspection methods, frequencies, and reaction plans across prototype, pre-launch,

npx playbooks add skill robdtaylor/personal-ai-infrastructure --skill controlplan

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SKILL.md
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---
name: Controlplan
description: Generate AIAG-format Control Plans linked to PFMEAs with proper inspection methods, frequencies, and reaction plans. Supports Prototype/Pre-launch/Production phases. USE WHEN user says 'control plan', 'CP', 'inspection plan', 'process control', 'sampling frequency', 'reaction plan', or 'special characteristics'. Integrates with PFMEA, AutomotiveManufacturing, and MSA skills.
---

# Control Plan

## When to Activate This Skill
- "Create a control plan for [part/process]"
- "What inspection frequency for [characteristic]?"
- "Define control methods for [operation]"
- "Link PFMEA to control plan"
- "What's the reaction plan for [out-of-spec condition]?"
- "Develop prototype/pre-launch/production control plan"

## Control Plan Phases

### Prototype Control Plan
- **Purpose**: Control during prototype build
- **Focus**: Dimensional measurements, material tests, performance
- **Frequency**: Often 100% on critical dimensions
- **Duration**: Until prototype approval

### Pre-Launch Control Plan
- **Purpose**: Control during PPAP/validation runs
- **Focus**: Enhanced inspection, process validation
- **Frequency**: Increased sampling, SPC establishment
- **Duration**: Until production approval (PSW)

### Production Control Plan
- **Purpose**: Ongoing production control
- **Focus**: Standardized controls, sustained quality
- **Frequency**: Based on process capability
- **Duration**: Life of production

## AIAG Control Plan Format

### Required Columns

| Column | Description | Source |
|--------|-------------|--------|
| Part/Process Number | Operation step number | Process Flow |
| Process Name/Description | Operation description | Process Flow |
| Machine/Device/Jig/Tool | Equipment used | Process documentation |
| Characteristic Number | Unique ID for characteristic | Sequential |
| Product Characteristic | Part feature being controlled | Drawing, spec |
| Process Characteristic | Process parameter affecting product | PFMEA |
| Special Char Class | CC, SC, or blank | PFMEA/Drawing |
| Product/Process Spec | Tolerance or requirement | Drawing, spec |
| Evaluation/Measurement | Gage/method used | MSA |
| Sample Size | Quantity inspected | Based on risk |
| Sample Frequency | How often inspection occurs | Based on risk |
| Control Method | How results are recorded/used | SPC, checklist, etc. |
| Reaction Plan | Action when out of spec | Defined response |

## Special Characteristics

### Critical Characteristics (CC)
- **Symbol**: Shield, (CC), or inverted delta
- **Criteria**: Safety or regulatory compliance
- **Requirements**:
  - Documented in Control Plan
  - Enhanced inspection (often 100%)
  - SPC required (Cpk ≥1.67)
  - Traceable records
  - Identified on drawing

### Significant Characteristics (SC)
- **Symbol**: Diamond, (SC)
- **Criteria**: Fit, function, appearance significant to customer
- **Requirements**:
  - Documented in Control Plan
  - Appropriate inspection frequency
  - SPC recommended (Cpk ≥1.33)
  - Records maintained

### Standard Characteristics
- **Symbol**: None
- **Criteria**: All other characteristics
- **Requirements**:
  - Documented in Control Plan
  - Sampling based on risk
  - Records as required

## Sample Size and Frequency Guidelines

### Based on Severity (from PFMEA)

| Severity | Sample Size | Frequency | Rationale |
|----------|-------------|-----------|-----------|
| 9-10 (Safety) | 100% | Every piece | Safety critical - no escape |
| 7-8 (High) | 100% or n≥5 | Per hour or per lot | High customer impact |
| 5-6 (Moderate) | n≥3 | Per shift or per setup | Moderate risk |
| 1-4 (Low) | n≥1 | Per lot or periodic | Low risk |

### Based on Process Capability

| Cpk Range | Typical Frequency | Notes |
|-----------|-------------------|-------|
| <1.00 | 100% or very frequent | Process not capable |
| 1.00-1.33 | Every hour or more | Marginal capability |
| 1.33-1.67 | Per shift or setup | Capable |
| >1.67 | Per setup, daily, or lot | Highly capable |

### Standard Frequency Terms

| Term | Meaning | When to Use |
|------|---------|-------------|
| Continuous | 100% inspection | Safety, high risk |
| Per piece | Every part | Critical characteristics |
| Per hour | n pieces every hour | SPC, high-risk |
| Per shift | Start and end of shift | Setup-sensitive |
| Per setup | At setup only | Stable characteristics |
| Per lot | One sample per production lot | Low-risk, stable |
| Daily | Once per day | Periodic verification |
| Weekly | Once per week | Very stable |

## Control Methods

### Inspection Methods

| Method | Description | Typical Use |
|--------|-------------|-------------|
| Visual | Operator observation | Surface defects, presence |
| Go/No-Go Gage | Attribute check | Hole size, thread, profile |
| Caliper/Micrometer | Variable measurement | Dimensions |
| CMM | Coordinate measurement | Complex features |
| Height Gage | Surface plate measurement | Flatness, position |
| Profilometer | Surface finish | Ra, Rz |
| Hardness Tester | Material property | HRC, HRB |
| Torque Wrench | Fastener torque | Assembly |
| Leak Test | Seal integrity | Fluid systems |
| Functional Test | Performance verification | End-of-line |

### Recording Methods

| Method | Description | When to Use |
|--------|-------------|-------------|
| Check Sheet | Attribute recording | Visual checks, presence |
| Data Log | Variable data recording | Measurements |
| SPC Chart | Statistical control chart | Critical/significant |
| Traveler | Part-specific record | Traceability |
| Electronic | MES/database entry | High volume |
| None (process control) | Poka-yoke, automated | Error-proofed |

## Reaction Plans

### Standard Reaction Plan Format

```
IF [out-of-spec condition] THEN:
1. STOP - Halt production/segregate suspect
2. CONTAIN - Quarantine affected parts
3. NOTIFY - Alert supervisor/quality
4. EVALUATE - Determine root cause and extent
5. CORRECT - Implement fix before restart
6. VERIFY - Confirm correction effective
```

### Reaction Plan Examples

**Dimension Out of Spec:**
1. Stop production
2. Segregate last good part to current
3. Notify Quality/Supervisor
4. Check tool condition, offset, fixture
5. Adjust/replace as needed
6. Run first piece, verify to spec
7. Inspect segregated parts 100%

**Visual Defect:**
1. Reject defective part
2. Assess severity (isolated vs trend)
3. If trend: notify supervisor, review process
4. Identify root cause (tool, material, handling)
5. Implement correction
6. Resume with enhanced attention

**SPC Out of Control:**
1. Mark control chart
2. Continue production if within spec
3. Investigate pattern (rule violated)
4. Identify assignable cause
5. Implement correction
6. Document on chart

## PFMEA to Control Plan Linkage

### Required Flow

```
PFMEA Item            →    Control Plan Entry
─────────────────          ───────────────────
Process Step          →    Part/Process Number
Function              →    Characteristic
Failure Mode          →    What we're preventing
Detection Control     →    Control Method
S/O/D Ratings         →    Sample Size/Frequency
Special Char          →    Special Char Class
```

### Linkage Verification

For each Control Plan line, verify:
- [ ] PFMEA has corresponding failure mode
- [ ] Special characteristics match
- [ ] Control method addresses PFMEA detection
- [ ] Frequency appropriate for risk level
- [ ] Reaction plan defined

## Output Format

When generating Control Plan content:

```markdown
# Control Plan
**Part Number**: [P/N]
**Part Name**: [Description]
**Customer**: [Customer Name]
**Control Plan Number**: CP-[DEPT]-[SEQ]
**Phase**: [ ] Prototype  [ ] Pre-Launch  [X] Production
**Revision**: [Rev] | **Date**: [YYYY-MM-DD]
**PFMEA Reference**: PFMEA-[XXX]

## Operation: [Number] - [Name]

### Characteristic 1: [Description]

| Field | Value |
|-------|-------|
| **Char No.** | [Unique ID] |
| **Product/Process** | Product / Process |
| **Class** | CC / SC / - |
| **Specification** | [Nominal ± Tolerance] |
| **Evaluation Method** | [Gage/Equipment] |
| **Sample Size** | [n] |
| **Sample Frequency** | [When] |
| **Control Method** | [Recording method] |
| **Reaction Plan** | [Reference or inline] |
```

## Integration with Related Skills

### PFMEA
Control Plan is direct output of PFMEA:
- Every PFMEA detection control → Control Plan method
- PFMEA severity drives inspection frequency
- PFMEA updates trigger Control Plan review

**Load:** `read ~/.claude/skills/Pfmea/SKILL.md`

### MSA
All gages in Control Plan require MSA:
- Gage R&R for variable gages
- Attribute agreement for attribute gages
- MSA acceptance before production approval

**Load:** `read ~/.claude/skills/Msa/SKILL.md`

### AutomotiveManufacturing
Work instructions must reflect Control Plan:
- Inspection steps in work instructions
- Operator-level control methods
- Quality checkpoints documented

**Load:** `read ~/.claude/skills/Automotivemanufacturing/SKILL.md`

## Supplementary Resources

For detailed guidance:
`read ~/.claude/skills/Controlplan/CLAUDE.md`

For templates:
`read ~/.claude/skills/Controlplan/templates/control-plan-template.md`

For control method selection:
`read ~/.claude/skills/Controlplan/reference/control-methods.md`

For sampling guidelines:
`read ~/.claude/skills/Controlplan/reference/sample-frequencies.md`

Overview

This skill generates AIAG-format Control Plans linked to PFMEAs, with inspection methods, sampling frequencies, and reaction plans for Prototype, Pre-launch, and Production phases. It produces structured control plan entries that map PFMEA items to control methods, sample sizes, and documented responses for out-of-spec conditions. The output is ready for integration into work instructions, MSA activities, and production quality systems.

How this skill works

The skill reads PFMEA inputs (process steps, failure modes, severity/detection ratings, and special characteristics) and converts them into Control Plan lines using AIAG format fields: characteristic IDs, spec, gage/method, sample size, sample frequency, control method, and reaction plan. It applies severity and Cpk rules to set sampling frequency and flags CC/SC requirements. It can output phase-specific plans (Prototype / Pre-launch / Production) and link to MSA and Manufacturing steps for traceability.

When to use it

  • When asked to 'create a control plan', 'CP', or 'inspection plan' for a part or process
  • When linking PFMEA items to specific inspections and reaction plans
  • When defining sampling frequency for a characteristic or process parameter
  • When establishing controls for Prototype, Pre-launch (PPAP) or Production phases
  • When designating special characteristics (CC/SC) and their inspection requirements

Best practices

  • Always link each Control Plan line to a PFMEA failure mode and detection/control entry
  • Use severity and Cpk guidance to choose sample size and frequency (safety = 100%)
  • Design reaction plans with immediate STOP/CONTAIN/NOTIFY/EVALUATE/CORRECT/VERIFY steps
  • Include MSA results for each gage before approving production-level inspections
  • Document traceability: Part/Process number, PFMEA reference, revision/date, and phase

Example use cases

  • Generate a Prototype Control Plan emphasizing 100% checks on critical prototype dimensions
  • Create a Pre-launch Control Plan to increase sampling and establish SPC during PPAP runs
  • Produce a Production Control Plan that scales frequency based on Cpk and PFMEA risk
  • Convert PFMEA detection controls into actionable inspection steps with reaction plans
  • Specify gage type and required MSA for each measurement used in the Control Plan

FAQ

How does severity affect sample size and frequency?

Severity drives inspection rigor: safety-critical (severity 9–10) requires 100% inspection; high severity (7–8) often 100% or frequent hourly checks; moderate (5–6) uses multiple samples per shift; low (1–4) can be per lot or periodic.

What reaction plan format do you generate?

A standard sequence: STOP, CONTAIN, NOTIFY, EVALUATE, CORRECT, VERIFY. Plans are tailored by failure mode (dimension, visual, SPC) with clear operator actions and escalation.