8D Gate

Free template · Word + PDF

Control plan template

A blank control plan form (landscape, Word and PDF) plus a filled example from a fictional press-fit case after an 8D. Free, no card.

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What is in the template

  • Header: Part, customer, plant, phase (prototype, pre-launch or production), control plan revision and the linked PFMEA revision.
  • Controls table: For each process step: product or process characteristic, special characteristic mark, specification, measurement method, sample size, frequency, control method, reaction plan and owner.
  • Revision history: What changed, when and why, for example the 8D number or the PFMEA row that triggered it.
  • Release check: A short list to run before the new revision goes to the line.

The columns are a generic set. If your customer prescribes a control plan format, use theirs; this form is a working draft or a starting point where no format is given.

The filled example

Pages 1–2 are the blank form. Page 3 shows a fictional housing with a pressed bushing (the same case as the PFMEA basics worked example). After an 8D on loose bushings, revision D adds a locating-pin check at each shift start, replaces a visual check with press stroke and force monitoring on every part, and adds a seeded master part that the monitor must reject before production starts. The revision history names the 8D and the PFMEA rows that triggered the change. All companies, people and data are invented.

Special characteristic symbols and rules come from your customer. 'SC' is a fictional placeholder.

Control plan vs PFMEA

The PFMEA is the risk analysis: what could go wrong and how likely it is to be prevented or detected. The control plan is the list of checks that actually run in production. Each detection control in the PFMEA should appear in the control plan, and the work instruction at the station should show the same check.

Quick checks before you release a revision

  • Every detection control in the PFMEA has a row here, with method, sample, frequency and owner.
  • Each reaction plan says what happens to parts made since the last good check, not only "stop and inform".
  • Automatic checks have their own verification (for example a master part at shift start).
  • The revision and date match the PFMEA revision and the work instruction at the station.
  • If your customer requires notification or approval of the change, it is done before implementation.

Updating the control plan after an 8D? Use the PFMEA and control plan update checklist and the D7 prevent recurrence guide.

Related

Advisory template, in English. Not a customer decision.