CONTROL PLAN DEVELOPMENT

quality control plans

SERVICE AREA:

IMEG was hired by a global marking and coding equipment manufacturer to develop Control Plans for critical manufacturing processes. This project followed a comprehensive PFMEA initiative and aimed to improve process control, quality assurance, and production consistency.

THE PROBLEM

Low process yields were reducing manufacturing efficiency and increasing waste
Inconsistent or nonexistent control methods across production lines
Lack of visibility into upstream process issues contributing to downstream defects
No standard method for updating or managing quality control documentation
Urgent need to deploy consistent, auditable, and sustainable process control strategies

production control methods

THE PLAN

Leveraging PFMEA insights, IMEG implemented a robust methodology to create and institutionalize Control Plans:

quality control plans

THE RESULTS

Developed detailed Control Plans for seven key process flows
Audited existing control methods and validated their effectiveness and sufficiency
Used developed PFMEAs and Risk Priority Numbers (RPN) to guide prioritization of corrective actions
Identified and addressed high-risk process steps with new or improved control methods
Enabled proactive failure mode prevention through continuous monitoring and process verification