Control Plans are the operational bridge between Process FMEA risk analysis and manufacturing execution. This report shows which production processes have documented control methods, detection strategies, and reaction plans per IATF 16949 and AIAG-VDA standards.
Overview
The Control Plans Report serves manufacturing quality engineers, process engineers, and configuration managers who need to track process control implementation status across the AEB system production workflow. The report aggregates all controlPlanItem and processStep work items project-wide, displays control documentation completeness, and cross-references PFMEA analysis to verify that each identified process risk has corresponding control measures.
Key Features:
- Executive Summary Cards — Total count of control plan items and process steps with blue color-coded status badges
- Document Inventory Table — All Control Plan Risksheet documents with per-document control item counts and direct access links
- Process Flow Integration — Cross-references to Process Flow wiki pages showing manufacturing sequence diagrams
- PFMEA Linkage — Connection to System PFMEA Report to validate that all processFailureMode items have corresponding control detection methods
- Control Plan Item Metrics — Real-time computation of total characteristics under manufacturing control
Report Components
Summary Cards
| Component | Description |
|---|
| Control Plan Items Card | Displays total count of controlPlanItem work items across all Control Plan documents. Indicates the scope of manufacturing process characteristics under control. Updated automatically as control plan items are added or removed in Risksheet. |
| Process Steps Card | Shows total count of processStep work items in the project. Represents the granularity of manufacturing process decomposition and the number of production workflow stages that have been documented. Displayed with blue color coding. |
| Card Styling | Uses Nextedy Solutions Fluent Design System styling with accent colors, subtle shadows, and responsive layout. Cards render as clickable sections that may drill down to filtered work item lists. |
Work Item Types
Control Plan Item
The controlPlanItem work item type represents individual process characteristics that require monitoring or inspection during manufacturing. Control plan items are the leaf entities in the control plan hierarchy, linked to parent processStep work items and to PFMEA failure modes via the control type and detection method fields.
| Property | Type | Default | Description |
|---|
| ID | String | Auto-generated | Unique identifier for the control plan item (e.g., CP-001, CP-ASN-005) |
| Title | String | Required | Name of the characteristic being controlled (e.g., Sensor Housing Thickness, Camera Lens Clarity) |
| Description | Text | Optional | Detailed specification of what is being measured, monitored, or inspected |
| Process Step | Link (parent) | Required | Reference to the parent processStep work item defining the manufacturing process stage |
| Characteristic | Link | Optional | Link to corresponding characteristic work item from Design space for design-to-process traceability |
| Failure Mode | Link | Optional | Link to related processFailureMode from PFMEA analysis to show what risk this control detects or prevents |
| Measurement Method | Enum | Required | Type of inspection or measurement technique (e.g., Gauge, Automated Vision, Manual Inspection, Statistical Test) |
| Sample Frequency | String | Required | How often samples are inspected (e.g., Every 100 units, 4x per shift, Per lot) |
| Sample Size | Integer | Required | Number of units per sample (e.g., 5, 10, 20) |
| Lower Spec Limit (LSL) | Decimal | Optional | Minimum acceptable value for the characteristic |
| Target Value | Decimal | Optional | Nominal or intended value for the characteristic |
| Upper Spec Limit (USL) | Decimal | Optional | Maximum acceptable value for the characteristic |
| Reaction Plan | Text | Optional | Corrective or containment actions if measurement is out of specification (e.g., Stop line and quarantine production, Increase sampling to 100% inspection) |
| Control Type | Enum | Prevention | Classification per ISO 26262 or FMEA methodology (e.g., Prevention, Detection, protective-measure) |
| Status | Enum | Draft | Workflow state indicating maturity (Draft, Approved, In Effect, Superseded) |
Process Step
The processStep work item type represents a discrete manufacturing process stage or production sequence point. Process steps are the parent entities for control plan items and are typically organized hierarchically within a production workflow (assembly, test, calibration, packaging). Process steps also appear as parent entities for processFailureMode items identified in PFMEA analysis.
| Property | Type | Default | Description |
|---|
| ID | String | Auto-generated | Unique identifier for the process step (e.g., PS-01, PS-ASN-02) |
| Title | String | Required | Name of the manufacturing process stage (e.g., Sensor Housing Assembly, Calibration, Burn-In Test) |
| Description | Text | Optional | Detailed procedure or work instructions for the process step |
| Sequence Number | Integer | Optional | Order in the manufacturing flow (e.g., 1, 2, 3) for process sequencing |
| Predecessor Step | Link | Optional | Reference to prior process step in the workflow for dependency tracking |
| Successor Step | Link | Optional | Reference to next process step for workflow sequencing |
| Equipment | String | Optional | Production equipment, machinery, or test fixtures used in this step |
| Personnel | String | Optional | Roles or skill levels required for the process step |
| Cycle Time (seconds) | Decimal | Optional | Target time to complete the process step |
| Rework Procedure | Text | Optional | Instructions for handling out-of-spec parts or failed tests |
| Related PFMEA Document | Link | Optional | Reference to the parent PFMEA document that analyzes risks in this process step |
| Status | Enum | Draft | Workflow state (Draft, Approved, In Production, On Hold) |
Document Structure and Configuration
Control Plan Risksheet Configuration
Control plans are implemented as Nextedy Risksheet documents, not PowerSheets. This tabular format enables efficient editing and updating of multiple control characteristics. The Risksheet configuration for Control Plans includes:
# Control Plan Risksheet column groups
column_groups:
- name: "Process Identification"
columns:
- field: "title"
label: "Characteristic"
width: "180px"
- field: "processStep"
label: "Process Step"
width: "150px"
- name: "Specification"
columns:
- field: "targetValue"
label: "Target"
width: "80px"
- field: "lowerSpecLimit"
label: "LSL"
width: "80px"
- field: "upperSpecLimit"
label: "USL"
width: "80px"
- name: "Control Method"
columns:
- field: "measurementMethod"
label: "Inspection Method"
width: "120px"
- field: "sampleFrequency"
label: "Frequency"
width: "100px"
- field: "sampleSize"
label: "Sample Size"
width: "80px"
- name: "Risk Response"
columns:
- field: "reactionPlan"
label: "Reaction Plan"
width: "200px"
- field: "failureMode"
label: "Related PFMEA"
width: "150px"
Process Flow Diagram Integration
Each manufacturing process flow is typically documented as a separate wiki page showing the sequence of process steps visually. The Control Plans Report links to these Process Flow diagrams, establishing the relationship between:
- Process Flow Diagram (visual workflow)
- Process Steps (work item entities)
- Control Plan Risksheet (detailed characteristics table)
- PFMEA Analysis (risk assessment for each step)
Example link pattern:
- Control Plan: AEB Sensor Unit Assembly
↓ (implements controls for)
- Process Flow: AEB Sensor Unit Assembly
↓ (identifies process steps)
- PFMEA: Process FMEA - AEB Sensor Unit
Metrics and Calculations
Control Plan Item Count
The report computes the total number of controlPlanItem work items project-wide using a Lucene query:
project.id:$projectId AND type:controlPlanItem
A higher control plan item count indicates more granular process control documentation. However, the quality of controls (not just quantity) is critical — each control should address a corresponding PFMEA risk or design characteristic specification.
Process Step Count
The report displays the total count of processStep work items via:
project.id:$projectId AND type:processStep
Per-Document Control Item Distribution
The Control Plan Risksheet documents in the Risks space are automatically discovered by naming convention. Each document’s control items are counted and displayed in an inventory table showing:
| Column | Meaning |
|---|
| Document Name | Title of the Control Plan Risksheet (e.g., “Control Plan - AEB Sensor Unit”) |
| Process | Associated manufacturing process or assembly |
| Item Count | Number of controlPlanItem work items in this document |
| Status | Document workflow state (Draft, Approved, In Effect) |
| Link | Direct access to the Risksheet for detailed editing |
Integration with PFMEA Analysis
The Control Plans Report cross-references the System PFMEA Report to establish the PFMEA-to-Control-Plan workflow:
PFMEA-to-Control-Plan Relationship
Each processFailureMode identified in PFMEA should have a corresponding controlPlanItem that defines:
- Prevention Control — Methods to prevent the failure from occurring (reduce Occurrence)
- Detection Control — Methods to detect the failure before customer impact (reduce Detection rating)
- Reaction Plan — Actions when an out-of-control condition is detected
The report verifies this linkage by checking that:
- All high-RPN process failure modes have corresponding control plan items
- Control plan items reference the failure modes they mitigate
- Detection methods in the control plan correspond to the FMEA detection strategy
Accessing the Report
Navigation Path
The Control Plans Report is accessible from:
- Home Dashboard — Reports section, click “Control Plans Report” button
- Risks Space Dashboard — Control Plans Report link in the reports section
- FMEA Reports Overview — Related reports section linking to all FMEA-related reports
- Direct URL —
<project>/wiki/<project>/spaces/Risks/Control Plans Report
Report Context
The report automatically filters to the current project. All metrics and document links are project-specific. If accessed from a template project, the report will show template control plan configurations.
Related Pages
