Module 18 · Quality
A Control Plan that is derived, not retyped. Rows are generated from the prevention and detection controls in the PFMEA, each field showing where it came from. When the risk analysis moves, a sync preview shows exactly what would change — and what an engineer wrote by hand is never overwritten.
What it does
Six capabilities, each tied to a decision your team is already trying to make.
Characteristics, controls and methods flow in from the PFMEA and the process flow. Every field shows its provenance — derived, overridden or authored — so a reviewer can see at a glance what came from the risk analysis and what was added on the floor.
When the PFMEA changes, the Control Plan shows the difference before anything is applied: rows added, controls changed, overrides gone stale, rows orphaned. Apply it in one click. Authored fields are never touched.
All three Control Plan phases from the same process definition, plus Safe Launch controls with exit criteria for the ramp-up. Pass-through characteristics get their own register, so nothing the customer sees is left unowned.
Standard reaction plans written once and referenced on every row that needs them. A row without a reaction plan is flagged before release — not discovered by the operator at 2 a.m.
Each station gets its own tablet view of exactly the controls it must run, opened from a QR code. The operator sees the current released revision — never a printout from two changes ago.
Engineering offers each control to operations, and operations sets it up, links an existing check or declines with a reason. The Control Plan row then shows whether the control is really running in In-Process Quality & SPC or Inspection. Connected, not coupled.
More than fifty checks — a special characteristic with no control, a gauge with no measurement system study, a row the PFMEA no longer supports — many with a one-click fix. Release with approvals, e-signature and a customer re-approval prompt when it is required.
Standards & Compliance
Better Together
Zometric's modules share a single data backbone — adopting more of them compounds the signal-to-noise advantage.
DFMEA, PFMEA and FMEA-MSR on the AIAG-VDA 7-step method — Action Priority computed live, and every failure chain linked to the control that manages it.
The process backbone — every step defined once and shared by the PFMEA and the Control Plan, as a table and as a diagram.
Catch process deviations before they become defects.
Statistically valid lot acceptance — replacing paper and Excel inspection.
A 30-minute discovery call. A 2–3 week pilot on real factory data. Then scale at your pace.
