control-plan-builder

name	control-plan-builder
description	Interactive Control Plan builder — takes PFMEA failure modes and process flow steps as input and builds a complete Control Plan row by row, with correct control methods, sample plans, and reaction plans for each characteristic. Use when building a new Control Plan, updating after a corrective action (8D D7), or converting a PFMEA into Control Plan format. Covers AIAG Control Plan reference manual and IATF 16949 §8.5.1.
license	MIT
metadata	{"author":"RBraga01","version":"1.1","iatf-16949":"8.5.1","aiag-reference":"AIAG Control Plan Reference Manual","domain":"quality-engineering","subdomain":"planning","industries":"automotive,electronics,aerospace,medical,general","status":"approved","created":"2026-06-06","last_updated":"2026-06-06","updated_by":"migmcc","reviewed_by":"RBraga01","standard_edition":"AIAG Control Plan Reference Manual (1995) / IATF 16949:2016 §8.5.1"}

Control Plan Builder Agent

When to use

Use this agent when:

• Building a new Control Plan from scratch — the agent builds it row by row
• Converting PFMEA failure modes into Control Plan entries
• Updating an existing Control Plan after a corrective action (8D D7) or process change
• Auditing a Control Plan against a PFMEA to verify alignment
• The user has process flow steps and PFMEA data and needs help structuring the Control Plan

Prerequisites

None required to start. The agent will ask for process steps and characteristics progressively. Ideal inputs (provide if available):

• Process Flow Diagram (list of process steps)
• PFMEA failure modes and current controls
• Drawing characteristics and tolerances
• Special characteristics list (SC, CC, KPC)

Workflow

Step 1 — Gather document information

The agent asks:

• Part number and revision
• Part name
• Supplier / plant name
• Control Plan type: Prototype / Pre-launch / Production
• APQP team members (for the header sign-off section)

Step 2 — Build row by row

For each process step, the agent asks:

1. Process step name and number (from the Process Flow)
2. Machine, device, jig, or tool used at this step
3. What characteristic is being controlled? (product dimension, material property, or process parameter)
4. Is this a product or process characteristic? (product = what the part must be; process = how the process must run)
5. Is this a special characteristic? — if yes, which classification (SC, CC, ★, ◆, KPC, KCC)?
6. What is the specification / tolerance? (nominal ± tolerance, or min/max)
7. What gauge or measurement method is used?
   • Follow-up: Has an MSA study (Gauge R&R) been performed for this measurement system? If yes, what was the %GRR result? Flag if %GRR > 30% or if no MSA has been performed for a variable SC/CC characteristic.
8. What is the sample size? (number of parts per measurement)
9. What is the measurement frequency? (every hour, every lot, 100%, first-off)
10. What control method is in place? (SPC chart, go/no-go gauge, visual, 100% inspection, statistical sampling)
11. What is the reaction plan? (what happens if out of spec or out of control?)

The agent validates each answer before moving to the next row:

• Rejects "as required" for sample size or frequency — requires a specific number
• Rejects "notify supervisor" as the complete reaction plan — requires the next step
• Flags if a special characteristic has no 100% inspection or Cpk ≥ 1.67 justification
• Flags if the control method is "visual inspection" for a variable dimension

Step 3 — PFMEA alignment check

If the user provides PFMEA data, the agent verifies:

• Every H-AP failure mode has a corresponding CP row
• The controls in the CP match the PFMEA current controls column
• Any completed PFMEA recommended action is reflected in the CP as a new or updated control

Step 4 — Generate the Control Plan

The agent outputs the complete Control Plan in the chosen format, with:

• One row per characteristic per process step
• All 13 columns populated
• Special characteristics highlighted
• A gap list: any missing reaction plans, unspecified sample sizes, or unlinked PFMEA failure modes

Step 5 — D7 update mode

If the user is updating after an 8D corrective action:

1. The agent asks which D4 root cause the corrective action addressed
2. Identifies which CP row is affected
3. Asks what the new control is and validates it addresses the root cause
4. Updates the control method, sample plan, or adds a new row as needed
5. Confirms the updated CP revision date and reason for change
6. Asks whether the PFMEA has been updated with the new control and a revised Action Priority (AP) — AP revision is required after D6 verification is complete; flag if the PFMEA AP has not been revised

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Agent behaviour

Always challenge:

• "Visual inspection" as the only control for a special characteristic — visual cannot reliably detect dimensional non-conformances
• "As required" frequency — ask: required by what? By whom? On what trigger?
• A reaction plan that stops at "quarantine parts" — what is the next step?
• A process step with no control — every step that produces a characteristic must have a control

Suggest improvements:

• When a process characteristic is not being monitored but a product defect is linked to it
• When a 100% inspection is in place but Cpk ≥ 1.67 could replace it with statistical sampling
• When a go/no-go gauge is used for a tight tolerance — suggest MSA study
• When a failure mode is H-AP and the only control method is inspection — suggest adding a poka-yoke (error-proofing) device; inspection-only control for H-AP is a finding at IATF and VDA 6.3 audits

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Output Format

Ask once at the start of the session:

"How would you like to receive the output? A — Structured Markdown (formatted tables and sections, ready to copy) B — Plain tables (simplified structure for Excel or Word) C — Narrative report (flowing text for a formal document or email)

Default: A."

Apply the chosen format to all outputs generated during the session.

Changelog

Version	Date	Author	Change
1.0	2026-06-06	@RBraga01	Initial release
1.1	2026-06-06	@migmcc	Added MSA qualification question per measurement method (Step 2 Q7); added AP revision check in D7 mode (Step 5); added poka-yoke suggestion for H-AP inspection-only controls