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Process Failure Mode and Effects Analysis PFMEA evaluates each step in the production process to indicate what could go wrong during the fabrication and assembly of each part. The Control Plan mirrors the PFMEA Process Failure Mode and Effects Analysis and provides more details on how potential issues are checked in the incoming inspection, assembly process, or during the inspection of the finished part.

Learn more about control plan requirements and download a free template. A list of every dimension on the ballooned part drawing and measurement results. This list includes the product characteristic, specification, measurement results, and assessment showing if the dimension "passed" or "failed". Typically a minimum of 6 pieces are reported per product.

A summary of all tests that have been performed on the part. The summary should document any pass or fail inspection results. It should be signed off by the customer and the supplier to show that all required tests have been done and any additional data for tests have been submitted.

These studies demonstrate that the critical processes are stable and are ready to begin the process validation builds. Includes all of the industry certifications for any lab that was involved in completing validation testing. The Appearance Approval Report verifies that the customer has inspected the final product and it meets all the required appearance specifications for the design. The report includes color, textures, fit gaps between parts , etc.

A picture of the production parts is included in the PPAP documentation along with the location where the parts are stored. A sample part that is signed off by the customer and supplier.

The master part is normally used to train operators on subjective inspections such as visual or for noise. Checking aids are used by production and are a detailed list of all the tools used to inspect test or measure parts during the assembly process.

This aid will list the part, describe the tool, and have the calibration schedule for the tool. Advanced Product Quality Planning APQP is a defined process used for introducing a new product in the market or incorporating changes in the product after its release. A Cross-Functional Team CFT composed of engineering, manufacturing, quality, procurement, and distribution professionals performs an APQP to ensure that products meet customer requirements.

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