Towards a unified control plan - a method for integrating and evaluating automated control plans in manufacturing systems

Control plans are built around diverse monitoring systems that are crucial in implementing a manufacturer’s quality strategy. However, maintaining applicable, relevant, and up-to-date control plans remains challenging due to increasing product variety, changing equipment and processes, and high expert turnover. In the Industry 4.0 context, where quality control is automated, there is a lack of integration between monitoring systems and their associated control plans. This hinders the ability to track the evolution of control plans across their design, configuration, and execution phases. Addressing these challenges, a Reference Data Model (RDM) was developed to map the relationships between quality and production components and monitoring systems. This model generates automated control plans in compliance with industry standards. To comprehensively evaluate the effectiveness of the control strategy, a Control Plan Performance Effectiveness (CPPE) indicator was proposed to facilitate the control plan review process. The CPPE comprises three metrics – completeness of control, realization of sampling, and quality of control equipment – and supports the Zero Defect Manufacturing (ZDM) strategy by ensuring a ‘first-time-right’ approach to quality control. The application of this indicator was illustrated through two case studies from the semiconductor industry, where the CPPE successfully identified areas of poor detection and redundant control methods.