Quality Control Plan And Why You Need One

So, you have an idea for a product you want your company to manufacture. The designs are complete, and your team is all on board, now what? Your next step is developing what’s called a quality control plan (QC Plan for short) is a description of the actions, tools and policies, and procedures needed to monitor an action that delivers a physical product or service. Its overall objective is to cut down and control a process.

It documents the steps necessary to maintain acceptable production rates. Its aim is to aid your company in producing quality products that meet the customers’ requirements. It’s a standardized approach for the design and implementation of efficient strategy’s and techniques for the total development and production system.

There are so many ways for companies to create an effective QC plan. Quality programs provide a written description of the methods and tactics used to minimize waste and variables throughout the manufacture or providing of services. The QC plan must be documented in an efficient, effective, and consistent manner so that you can replicate the results every time.

Today, let’s go over some of the means to construct and implement a full proof quality plan to make sure the goods or services you’re delivering for your company provides are efficient as possible.

Why Should I Use a QC Plan?

Think of a QC plan as the textbook for how your production operates. Having a single document that outlines your business’s’ production processes and product requirements will help optimize your workflow.

Top Lean Manufacturing Tools


Top Lean Manufacturing Tools

Download your FREE Top Lean Manufacturing Tools today. All the tools you need to know about Lean Manufacturing.

Setting your quality plan in the form of measurable variables to help you develop standard operating procedures for your employees to follow. Standard operating procedures help streamline your product production times and gives your employees strict guidelines to follow while ensuring a desirable product output.

Quality Control Planning For Your Business

Designing a quality program is one of the necessities that can directly affect the success of your business. Without a clear picture of what your company is doing and what it’s going to do, your plans won’t last very long.

QC Plans are what’s called a living document. A living document is a document that must always be adjusted to match the current processes and products you manufacture. Your quality control plans must match the current methods and systems that you are using.

Make sure you develop your QC plan early on in your products inception. A quality control plan gives you control that allows you to meet your exact specifications. Your first line of goods will be the products that will be showcased for sales, so you should make sure that that are of the utmost quality. Implementing a quality plan early on will act as a beacon to your staff to ensure your products are of the highest quality.

Another tactic to consider is having multiple QC plans in place if you have products that require different manufacturing processes. Include your QC plan with other documents that are necessary for production, like engineering drawings and other support documents. Coupling these documents together will ensure that your QC plan has been read, reviewed, and implemented.

Since the overall goal of a quality control plan is to improve the overall efficiency and quality improvement, your program covers the monitoring and control methods used and controls the characteristics and features of a process or product.

To create an effective control plan, you must have an intimate understanding of the required processes. If you lack said knowledge, consider putting together a team of specialists who can advise you during the planning process to ensure you have the best information at your disposal.

Here’s a list of the information you will need to get the ball rolling with creating your QC Plan:

  • Risk Assessment
  • Personal Notes
  • A List of Relevant Equipment and their capabilities
  • Design Plans
  • Process Flow Charts

Benefits of a Quality Control Plan

There are many advantages to implementing a well drafted, comprehensive control plan. To Break the benefits down, check the list below.

  • Quality: The most significant advantage of introducing a QC plan is that it develops and encourages excellence among your company’s employees, which will aid in obtaining the level of quality required by your standard operating procedures.
  • Customer Satisfaction: Happy clients who are satisfied with your products lead to repeat customers and positive feedback for your company.
  • Cuts Production Costs: By maintaining strict quality control increased and your costs are significantly reduced. Quality control also checks the sub-par products and wastes and saves you money on production.
  • Utilizes Conservation of Resources: QC Planning ensures you’re not wasting any material during the manufacturing process due to running at maximum efficiency, saving money and time.
  • Improved Workplace Environment: QC Plans develop more pleasant workplace environments and build better employee-employer relationships, leading to better rapport and teamwork.
  • Cuts Inspection Costs: Production means inspections. Implementing a well-planned QC plan will keep your business running efficiently. Having a well-maintained company will cut inspection costs considerably.
  • Boosts Employee Morale: Implementing the proper QC Plan will significantly reduce stress in the workplace, increasing employee morale, motivating them to produce high-quality products for your company.
  • Positive Public Image: Utilizing your business’s QC plan generates better products. Providing more top quality products satisfies the customer’s needs and provides a solution to their problem. This puts your business’s image in a positive light with the public, increasing your targeted demographics and increasing profits and stimulating growth.
  • Better Marketing: By providing the best quality product, word will spread that your business is one that is trustworthy and will always provide the best products. Word of mouth is one of the most efficient marketing methods there is.
  • Improved Production Methods: By providing a comprehensive engineering data for the manufacturing process, you’re ensuring your company is producing the highest quality product.
  • Fixed Prices: Introducing QC plans ensures that all the goods are manufactured with the same quality control measures in place, creating uniform products. Producing uniform products creates one standard price for all the goods.
  • Stimulates Sales: QC Plans ensures your products are of the utmost quality and stimulates more customers and growth in your client base. By maintaining regular customers and creating new customers, you have a consistent influx of sales.

How to Set Up a Comprehensive Plan

  1. The first step in creating your QC plan requires setting expectations, so you to have all the information on your customer and client’s needs, so you understand which steps you need to take to create your plan. Through receiving insight from your client, you will be able to set clear expectations and have an idea of where you need to set your targeted quality standards. Having insight from the customer will increase your chances of success with your product.
  2. Step two in setting up your QC plan is deciding is achieving proper quality assurance. Determine which equipment and methods for maintaining the expected quality levels during the project planning stage. Make sure you plan comprehensive quality assurance reviews on a regular basis. Hire a third-party specialist to conduct these reviews to ensure they’re as accurate as possible.
  3. Your quality control plan needs to include schedules and sequences of activities. Having a quality control template should help your company manage production quantities for your products. If you run into production errors, having schedules and sequences in order will aid in investigating any deviations of your expected product output. To properly utilize a quality control template, you should have peer to peer review boards, end of phase reviews and deliverable reviews.
  4. Now that you have taken care of the development of your quality assurance plan, the last process is developing a plan for quality management. A quality management plan is a set of guidelines to ensure that your quality control and quality assurance procedures are always followed to the letter. If you face any issues, a quality management plan can assist in finding any problems in your control program and dealing with them in the appropriate manner.

Key Take Aways for your Quality Control Plan

Designing and implementing a well-planned quality control program will take care of most of your business’s logistics and production procedures. Having set policies and procedures ensures your products are of the utmost quality, keeping your customers coming back and stimulating new growth for your business. Quality products also give your company a positive public image and provide organic marketing strategies to get put your business’s name on the map. Take your production output to the next level and put together a team of qualified personnel and write a comprehensive quality plan. It seems like a daunting task, but it’s very possible, and many companies have had great success with quality control programs. Talk to your customers and develop a list of their needs and wants and use that as a guide to which direction you need to aim your control plans. Remember you can utilize multiple quality assurance programs for various product lines. If your production standards are similar, you can usually cover production with one, comprehensive plan.

I hope you’ve gained a lot of insight and wisdom on creating your quality control plan and you have some perspective on how to efficiently plan and manage your business.

Author: Eric Raio

Eric Raio is one of the founders of Factory Solutions. When he isn't plotting new ways to create awesome software. He likes to geek out about flying drones and technology.

Other articles we think you'll love

Why are we asking?
Top Lean Manufacturing Tools

Top Lean Manufacturing Tools

10X Your Production
Download Your Free Top Lean Manufacturing Tools Guide

Take this 6-day mini course and reach new heights: