Control Plan Development and Implementation

Programme Summary

Translate product and process risks into practical controls that operators can use consistently. Participants build control plans linking characteristics, methods, sampling and reaction requirements with process flow and failure analysis. Exercises address changing production stages, measurement suitability and abnormal results, producing a controlled document that supports daily decisions and remains aligned with the way work is actually performed.

Training Objectives

1 Connect process risks with operational controls; 2 Define measurable characteristics and acceptance criteria; 3 Select practical measurement and sampling arrangements; 4 Clarify reaction actions and process ownership; 5 Maintain control plans through operational changes.

Learning Outcomes

1 Develop a process linked control plan; 2 Specify characteristic limits and measurement methods; 3 Define sampling frequency and reaction responsibilities; 4 Check consistency with flow and risk analysis; 5 Prepare a controlled update and verification plan.

Target Audience

Quality Engineers; Process Engineers; Quality Managers; Production Supervisors; Continuous Improvement Specialists.

Target Industries

Automotive Components; Electronics Manufacturing; Precision Machining; Plastics Manufacturing; Industrial Equipment Manufacturing.

Course Contents

• Module 1 Control Plan Purpose: Process performance and customer requirements; Planning launch and routine production stages; Control plan ownership and user needs.
• Module 2 Process and Risk Linkages: Process flow and operation identification; Failure modes and important characteristics; Consistency with product specifications and risk analysis.
• Module 3 Defining Characteristics: Product and process parameters; Limits tolerances and acceptance criteria; Special characteristics and traceable identifiers.
• Module 4 Measurement and Sampling: Suitable methods equipment and measurement capability; Sample quantities frequencies and rationale; Data recording and process monitoring needs.
• Module 5 Prevention and Reaction Controls: Prevention methods and mistake proofing checks; Abnormal result containment and escalation; Responsibilities for adjustment restart and release.
• Module 6 Work Instruction Interfaces: Usable instructions and visual references; Operator training and competence evidence; Record forms and practical execution checks.
• Module 7 Change and Review: Product process equipment and supplier changes; Updating linked documents and approvals; Effectiveness review and lessons learned.
• Module 8 Control Plan Workshop: Building a plan for a component; Checking links to process risk evidence; Testing the reaction plan against a deviation.

Assessment

• 40 single best answer questions, including applied scenarios; one mark per question.
• 60 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied reference pack and calculator permitted; external internet and AI prohibited.
• Individual applied assessment (30 minutes): Develop a control plan for a supplied process, justify monitoring arrangements and test the reaction plan against an abnormal result scenario.
• Assessment criteria: Clear risk to control traceability; Suitable measurement and sampling details; Effective reaction and ownership arrangements.
• Pass each component separately: 30/40 written marks (75%) and at least 70% on the applied task.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records control plan development skills; customer specific approval and operational release remain separate organisational responsibilities.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

222

Total teaching hoursTotal teaching hoursTotal teaching hours

12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Manufacturing or quality engineering experience is required. Basic familiarity with process flow, failure analysis and measurement systems is recommended.Manufacturing or quality engineering experience is required. Basic familiarity with process flow, failure analysis and measurement systems is recommended.Manufacturing or quality engineering experience is required. Basic familiarity with process flow, failure analysis and measurement systems is recommended.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Review a process flow and risk analysis extract for 25 minutes; identify characteristics needing controlled monitoring.Review a process flow and risk analysis extract for 25 minutes; identify characteristics needing controlled monitoring.Review a process flow and risk analysis extract for 25 minutes; identify characteristics needing controlled monitoring.

End of course assessmentEnd of course assessmentEnd of course assessment

40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.