Key Contact : Customer Information:

Date (orig)
Control Plan

Part name Date (rev)

Control Plan No
Control Plan issue
Product level Stage Level
Drawing No and Rev
FG OR1 Page
Assembly OR2
Part No and Rev
Part ü SOP ü
Characteristics Methods
Process name / Process Owner / Machine, Device, Special Char
Evaluation / measurement Sample Reaction Plan
Operation description expert Jig, tool for MFR Process Product Class Product/Process Spec / tolerance Reference Document Control Method
technique Size Frequency Duration Data captured

Obtained Mil cert/Supplier out going report/ Quarantine affected lot. Inform QA
Store Receiving procedure
Store Dept None Receiving None None Delivery order document. Visual Verification Every batch Every lot None Purchase Requested Receiving Instruction Engineer, Purchasing and Planner.
(Doc No/Rev:xxxx)
Issue Discrepancy Report

Digital Caliper
In-Coming Quality IQC checklist Quarantine affected lot and Escalate to
Thickness: 6.00＋0.50mm [Resolution: 0.01mm]
Control Checklist (Doc No/Rev:xxxx) QA Engineer to issue NCMR and inform
Range: 0-300mm
purchaser
Operation 1 Raw material - Coil
Raw Material None None 1 strip Every batch None
[Dimension]

Digital Caliper
In-Coming Quality IQC checklist Quarantine affected lot and Escalate to
Width: 300.00 [Internal Control] [Resolution: 0.01mm]
Quality Dept None Control Checklist (Doc No/Rev:xxxx) Sampling Inspection QA Engineer to issue NCMR and inform
Range: 0-300mm
purchaser

Material Grade: EG 6.0mmt

Colour: Natural
Raw material - Coil In-Coming Quality IQC checklist Quarantine affected lot and Escalate to
None None Visual verification 1 strip Every batch None
[Appearance] Visual: No dent, no dirt, no damage and no rust. Control Checklist (Doc No/Rev:xxxx) QA Engineer to issue NCMR and inform
purchaser
Raw material storage condition: Fully wrap with plastic cover

None Punch Tool Grade:HSS(High Speed Steel) Visual verification None Every setup None

Tool Service and

Maintenance Checklist
Tool Service and
Report Escalate to Tool Room Dept. Send the
Punch Tool Lifespan: 1 million Once reach 1 million Maintenance Checklist
Tool Room dept Tool Id: xxxxx Tool Setup None Machine Counter 1 million pieces Every pieces (Doc No/Rev:xxxx) Tooling Servicing tool for Full service. Provide the Tool
Replace every 2 million punch pieces Report / Tooling
Service Form & Last Strip/Part together.
Maintenance Record
Operation 2.1 Tooling Maintenance Record
Piercing None (Doc No/Rev:xxxx)
(Progressive Stamping)
Digital Caliper
Punch Tool Dimension:
None [Resolution: 0.01mm] None Every setup None
2 x Ø15.00mm
Range: 0-300mm

Stamping Machine: Die Height: 500mm Stop the machine. Inform production
Master Parameter
Prod dept Seyi Machine Setup None Stamping Oil Type: 20SYNPRESSFL -002 Visual verification None Every setup None Master Parameter Parameter Setup Supervisor and Tool Setter .Re-setup
(Doc No/Rev:xxxx)
Model: SNS-200 Pitch: 150.00 the tooling.
 None Punch Tool Grade:SKD 11 Visual verification None Every setup None

Tool Service and

Maintenance Checklist
Tool Service and
Report Escalate to Tool Room Dept. Send the
Punch Tool Lifespan: 1 million Once reach 1 million Maintenance Checklist
Tool Room dept Tool Id: xxxxx Tool Setup None Machine Counter 1 million pieces Every pieces (Doc No/Rev:xxxx) Tooling Servicing tool for Full service. Provide the Tool
Replace every 2 million punch pieces Report / Tooling
Service Form & Last Strip/Part together.
Maintenance Record
Operation 2.2 Tooling Maintenance Record
Countersink None (Doc No/Rev:xxxx)
(Progressive Stamping)
Digital Caliper
Punch Tool Diameter:
None [Resolution: 0.01mm] None Every setup None
2 x Ø25.00mm
Range: 0-300mm

Stamping Machine: Die Height: 500mm Stop the machine. Inform production
Master Parameter
Prod dept Seyi Machine Setup None Stamping Oil Type: 20SYNPRESSFL -002 Visual verification None Every setup None Master Parameter Parameter Setup Supervisor and Tool Setter .Re-setup
(Doc No/Rev:xxxx)
Model: SNS-200 Pitch: 150.00 the tooling.

None Punch Tool Grade:HSS(High Speed Steel) Visual verification None Every setup None Tool Service and
Maintenance Checklist
Tool Service and
Report Escalate to Tool Room Dept. Send the
Maintenance Checklist
Tool Room dept Tool Id: xxxxx Tool Setup (Doc No/Rev:xxxx) Tooling Servicing tool for Full service. Provide the Tool
Report / Tooling
Service Form & Last Strip/Part together.
Maintenance Record
Operation 2.3 Tooling Maintenance Record
Punch Tool Lifespan: 1 million Once reach 1 million (Doc No/Rev:xxxx)
Idle None None Machine Counter 1 million pieces Every pieces
Replace every 2 million punch pieces
(Progressive Stamping)

Stamping Machine: Die Height: 500mm Stop the machine. Inform production
Master Parameter
Prod dept Seyi Machine Setup None Stamping Oil Type: 20SYNPRESSFL -002 Visual verification None Every setup None Master Parameter Parameter Setup Supervisor and Tool Setter .Re-setup
(Doc No/Rev:xxxx)
Model: SNS-200 Pitch: 150.00 the tooling.

None Punch Tool Grade:HSS(High Speed Steel) Visual verification None Every setup None

Tool Service and

Maintenance Checklist
Tool Service and
Report Escalate to Tool Room Dept. Send the
Punch Tool Lifespan: 1 million Once reach 1 million Maintenance Checklist
Tool Room dept Tool Id: xxxxx Tool Setup None Machine Counter 1 million pieces Every pieces (Doc No/Rev:xxxx)) Tooling Servicing tool for Full service. Provide the Tool
Replace every 2 million punch pieces Report / Tooling
Service Form & Last Strip/Part together.
Operation 2.4 Maintenance Record
Tooling Maintenance Record
Trimming Hole & (Doc No/Rev:xxxx)
None
Part Cut Off
(Progressive Stamping)
Digital Caliper
Punch Tool Diameter:
None [Resolution: 0.01mm] None Every setup None
2 x Ø15.00mm
Range: 0-300mm

Stamping Machine: Die Height: 500mm Stop the machine. Inform production
Master Parameter
Prod dept Seyi Machine Setup None Stamping Oil Type: 20SYNPRESSFL -002 Visual verification None Every setup None Master Parameter Parameter Setup Supervisor and Tool Setter .Re-setup
(Doc No/Rev:xxxx)
Model: SNS-200 Pitch: 150.00 the tooling.

Ø310.10 ±0.35mm

R143.21 ±0.30mm

36.78 ±0.23mm Smartscope

Resolution:0.001ų 1 piece Every setup None
2 x Ø15.00mm Range: 170x150x80mm
None Escalate to tool setter, re-adjust
2 x Ø25.00mm First Article Inspection affected dimension
Semi-Finish Part First Article Inspection
None None Report 1st piece inspection (troubleshoot by tool maker). Re-
[Dimension] Report
(Doc No/Rev:xxxx) submission to QA approval to run mass
2 x 9.11 ±0.12mm Position max Ø0.20 datum AB production.

Digital Caliper
6.00 ＋ 0.5mm [Resolution: 0.01mm] 1 piece Every setup None
1st Setup Inspection Quality Dept Range: 0-300mm

Height Gauge
None 0.80 (Flatness) Resolution: 0.001ų 1 piece Every setup None
Range: 0-711mm

Visual: Escalate to tool setter, (troubleshoot by

None All edges on visual surface must be free from burrs and sharp Visual Verification 3pcs Every setup None tool maker). Re-submission to QA
edges approval to run mass production.
First Article Inspection
Semi-Finish Part First Article Inspection
None None Report 1st piece inspection
[Visual] Report
(Doc No/Rev:xxxx)
Handling Method: During handling, the cloth gloves
Clean Cloth gloves must be wear at all times during handling Until remain clean become dirty. Escalate to the production
▼ Visual Verification Handling every pieces Everytime
this part from part manufaturing, part packaging until part cloth gloves supervisor and request new cloth gloves
production assembly. to wear.
 Ø310.10 ±0.35mm

R143.21 ±0.30mm

2 x Ø15.00mm
Smartscope
2 x Ø25.00mm Resolution:0.001ų
Range: 170x150x80mm
None 36.78 ±0.23mm

2 x 9.11 ±0.12mm Position max Ø0.20 datum AB

Stop the production. Escalate to QA

Digital Caliper engineer/Production supervisor.
In Process Quality Control
Semi-Finish Part 6.00 ＋ 0.5mm [Resolution: 0.01mm] In Process Quality Quarantine affected lot. Escalate to tool
IPQC Inspection Quality Dept None None 2pcs Every 1 Hour None Report Interval Inspection
[Dimension] Range: 0-300mm Control Report setter, re-adjust affected dimension or
(Doc No/Rev:xxxx)
Send tool for repair (trouble shoot by
tool maker)
Height Gauge
None 0.80 (Flatness) Resolution: 0.001ų
Range: 0-711mm

Visual:
None All edges on visual surface must be free from burrs and sharp Visual Verification
edges

Handling Method:
Clean Cloth gloves must be wear at all times during handling
▼ Visual Verification
this part from part manufaturing, part packaging until part
production assembly.

Chemical name: Alkaline Liquid Degreaser

Chemical code: SPU 8-36L
Chemical Control Range: 7-10
Stop the production.Escalate to
Manual Degreasing Daily Maintenance Daily Maintenance Checklist
Manual Degreasing None PH Indicator Strips None Every 4 hour None Work Instruction Production leader/Supervisor or
[Mini Tank] Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
Soaking every 10 minutes before Pretreatment washer

Chemical name: Alkaline Liquid Degreaser Stop the production.Escalate to

Degreasing Daily Maintenance Daily Maintenance Checklist
None Chemical code: SPU 8-36L PH Indicator Strips None Every 4 hour None Work Instruction Production leader/Supervisor or
[Tank 1] Checklist (Doc No/Rev:xxxx)
Chemical Control Range: 7-10 Engineer to rectify.
Pretreatment
Washer
Chemical name:Iron Phosphating Solution Stop the production.Escalate to
Degreasing Daily Maintenance Daily Maintenance Checklist
None Chemical code: SPU 6-82 PH Indicator Strips None Every 4 hour None Work Instruction Production leader/Supervisor or
[Tank 3] Checklist (Doc No/Rev:xxxx)
Chemical Control Range: 7-10 Engineer to rectify.

Stop the production.Escalate to

Conveyor Line Daily Maintenance Daily Maintenance Checklist
Conveyor Line Speed: 400 rpm Tacho Meter None Every 1 hour None Work Instruction Production leader/Supervisor or
Speed Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
None
Stop the production.Escalate to
Oven Daily Maintenance Daily Maintenance Checklist
Pretreatment Oven Temperature Range: 120-130°c PLC Controller None Every 1 hour None Work Instruction Production leader/Supervisor or
Temperature(°c) Checklist (Doc No/Rev:xxxx)
Engineer to rectify.

Powder name: Oxyplast Stop the production.Escalate to

Daily Maintenance Daily Maintenance Checklist
None Powder code: PR12/7152/CT1 Visual Verification Every Batch Every Lot None Work Instruction Production leader/Supervisor or
Checklist (Doc No/Rev:xxxx)
Colour: Black Engineer to rectify.
Operation 3
Prod dept None
Powdercoat
Stop the production.Escalate to
Daily Maintenance Daily Maintenance Checklist
None Electrostatic spraying negative tension range: 60-80kV Machine Controller None Everyday None Work Instruction Production leader/Supervisor or
Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
Powder Coating
Stop the production.Escalate to
Daily Maintenance Daily Maintenance Checklist
None Air Pressure Range: 4-5 psi Pressure Gauge None Everyday None Work Instruction Production leader/Supervisor or
Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
Electrostatic Spray
Gun Controller
Stop the production.Escalate to
Surface Finishing: Black Powder Coating, 60-80micron Daily Maintenance Daily Maintenance Checklist
None Coating thickness gauge None Everyday None Work Instruction Production leader/Supervisor or
thickness Checklist (Doc No/Rev:xxxx)
Engineer to rectify.

Stop the production.Escalate to

Spray Nozzle Life Spray Nozzle: 1007-684 Replace every 3 Daily Maintenance Daily Maintenance Checklist
None Visual verification None Everyday Work Instruction Production leader/Supervisor or
Span Standard size months Checklist (Doc No/Rev:xxxx)
Engineer to rectify.

Stop the production.Escalate to

Spray Nozzle Life Insert Sleeve: 1006-485 Replace every 3 Daily Maintenance Daily Maintenance Checklist
None Visual verification None Everyday Work Instruction Production leader/Supervisor or
Span Standard size months Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
 Stop the production.Escalate to
Powder Coat Curing Daily Maintenance Daily Maintenance Checklist
None Curing Time: 19-20 minutes Timer None Everyday None Work Instruction Production leader/Supervisor or
Time Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
Powder Coat Oven
Stop the production.Escalate to
Powder Coat Curing Daily Maintenance Daily Maintenance Checklist
None Temperature Range: 215-225°c PLC Controller None Every 1 hour None Work Instruction Production leader/Supervisor or
Temperature(°c) Checklist (Doc No/Rev:xxxx)
Engineer to rectify.
 Digital Caliper
None 1.50＋0.50mm [Resolution: 0.01mm] 1 piece Every setup None
Range: 0-300mm
Escalate to production
First Article Inspection
Finish Part Scratch Resistance Test Nichiban Panfix Cellulose Tape First Article Inspection supervisor/engineer, re-adjust affected
None None None 1 piece Every setup None Report 1st piece inspection
[Dimension] [ADHESIVE TEST] [Size 25mm] Report dimension .Re-submission to QA
(Doc No/Rev:xxxx)
approval to run mass production.
Coating thickness gauge
None Powder Coating: 60-80micron thickness Resolution:0.001ų 1 piece Every setup None
Range: 0-2000um

Escalate to the production

supervisor/engineer. Rectify the
1st Setup Inspection Quality Dept None Part to be free from oil,rust,finger prints and stain marks. Visual Verification 3pcs Every setup None degreasing pH level & handling method.
Re-submission to QA approval to run
mass production.

First Article Inspection Escalate to production

Finish Part Visual: First Article Inspection
None None Report 1st piece inspection supervisor/engineer, re-adjust affected
[Visual] None All edges on visual surface must be free from burrs and sharp Visual Verification 3pcs Every setup None Report
(Doc No/Rev:xxxx) dimension .Re-submission to QA
edges
approval to run mass production.

Handling Method: During handling, the cloth gloves

Clean Cloth gloves must be wear at all times during handling Until remain clean become dirty. Escalate to the production
▼ Visual Verification Handling every pieces Everytime
this part from part manufaturing, part packaging until part cloth gloves supervisor and request new cloth gloves
production assembly. to wear.

Digital Caliper
6.00＋0.50mm [Resolution: 0.01mm] 2pcs Every 1 Hour None
Range: 0-300mm
None
Stop the production. Escalate to QA
In Process Quality Control
Finish Part Scratch Resistance Test Nichiban Panfix Cellulose Tape In Process Quality engineer/Production supervisor. On-
None None 1 piece Every 4 hour None Report Interval Inspection
[Dimension] [ADHESIVE TEST] [Size 25mm] Control Report hold affected lot. Escalate to engineer
(Doc No/Rev:xxxx)
to rectify.

Coating thickness gauge

None Powder Coating: 60-80micron thickness Resolution:0.001ų 2pcs Every 1 Hour None
Range: 0-2000um

IPQC Inspection Quality Dept Visual:

None Visual Verification 5pcs Every 1 Hour None
Part to be free from oil,rust,finger prints and stain marks
Escalate to QA engineer/Production
supervisor. On-hold affected lot. Issue
NCMR for dispostion.
Visual: In Process Quality Control
Finish Part None All edges on visual surface must be free from burrs and sharp Visual Verification 5pcs Every 1 Hour None In Process Quality
None None Report Interval Inspection
[Visual] edges Control Report
(Doc No/Rev:xxxx)

Handling Method: During handling, the cloth gloves

Clean Cloth gloves must be wear at all times during handling Until remain clean become dirty. Escalate to the production
▼ Visual Verification Handling every pieces Everytime
this part from part manufaturing, part packaging until part cloth gloves supervisor and request new cloth gloves
production assembly. to wear.

Smartscope
None Ø310.10 ±0.35mm Resolution:0.001ų
Range: 170x150x80mm Escalate to QA engineer/Production
Finish Part Out-going Quality Outgoing Quality Control
None None 5pcs Every lot None Sampling Inspection supervisor. On-hold affected lot. Issue
[Dimension] Control Report (Doc No/Rev:xxxx)
NCMR for dispostion.
Digital Caliper
None 6.00＋0.50mm [Resolution: 0.01mm]
Range: 0-300mm

Visual:
None Visual Verification Sampling Size Every lot None
Part to be free from oil,rust,finger prints and stain marks
OQC Inspection Quality Dept Escalate to QA engineer/Production
supervisor. On-hold affected lot. Issue
NCMR for dispostion.
Visual:
Finish Part Out-going Quality Outgoing Quality Control
None None None All edges on visual surface must be free from burrs and sharp Visual Verification Sampling Size Every lot None Sampling Inspection
[Visual] Control Report (Doc No/Rev:xxxx)
edges

Handling Method: During handling, the cloth gloves

Clean Cloth gloves must be wear at all times during handling Until remain clean become dirty. Escalate to the production
▼ Visual Verification Handling every pieces Everytime
this part from part manufaturing, part packaging until part cloth gloves supervisor and request new cloth gloves
production assembly. to wear.

Packaging Specification Standard Operation Stop the production. Escalate to

Operation 4 Manual Count/ Standard Operation
Prod Dept None Packing None None Quantity per carton: 4 pcs None Every pieces None Procedure Work Instruction production supervisor. On-hold the
Packaging Visual Verification Procedure
Quantity per plastic bag : 1 piece (Doc No/Rev:xxxx) affected lot to re-count.