TS audit - finding related to old control plans

Long ago I had a minor non-conformance because my Control Plan did not have the error-proofing in the Control method. The auditor picked that up by looking at Annex A. If there was no change in the way you do things and there were no customer complaints which warrant a review of the Control Plan then there should not be a non-conformance. Hope this helps.

 

OK I understand that you have such a stable process that there is no need to audit the Control Plan. How are you conducting your Manufacturing Process audit then? Do you walk the Control Plan? If so that observations, OFI's, and NC's do you find internally? If you find opportunities for improvement, that warrants a change in your PFMEA and Control Plan.

 

If you have to revise the Control Plan and the revision impacts the customer specification, then you may have to re-submit a PSW to be signed. Once again these PPAP documents are supposed to be living documents and must be understood by everyone in OP that is affected by it.

 

You do not need to do that if the correction is simple and the risk to the OEM is low.

 

I agree with Andy. Control Plans are documents. What is your policy for review of documents? So if the auditor issue a formal nonconformance it should be a minor against 4.2.4 and your document control policy.

 

If it is found as part of a third party audit, you do. Otherwise you can't get your "non-conformance" closed.

 

No we are supplying the customer with products which were designed/developed/validated/approved in accordance with the applicable requirements at the time, prior to TS (and in many cases ISO) even being a thought. And we go about supplying those products for years without incident. Then along comes some guy saying "you missed a box here" without consideration of the semantics and/or effect of the "miss" and/or whether newer plans are compliant. Next thing you know, you are "updating" all your older control plans to fix the wording. Clearly that's value added.

 

Isn't the control plan a controlled document and as such, irrespective of any changes that were or were not needed to your original cp, wouldn't that document be required to have been reviewed (and part of that review should include a review to update it for new requirements/regulations, etc.) on at least an "X" basis of time?

 

As a manufacturing tool, control plan is a document that is prone to updating. Hence, the requirement mentioned in ISO/TS 16949 clause 7.5.1.1 which specifies that "Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing process, measurement, logistics, supply sources or FMEA (see 7.1.4)". Due to the proneness of being updated, those organizations who need to demonstrate conformity with ISO/TS must take into account the "shalls" of ISO/TS. Unfortunately, one of the "shalls" says "The organization shall develop a control plan that includes, as a minimum, the following contents...". - and this is stated in Annex A.