Module 1. Fundamentals and Key Changes of Control Plan 1st Edition: Purpose, transition of content previously included in APQP, and relationship with APQP 3rd Edition, IATF 16949, PPAP, and CSR.

Module 2. Inputs and Traceability for Control Plan Development: Process Flow Diagram, PFMEA, drawings/specifications, special characteristics, MSA/SPC, lessons learned, and customer requirements.

Module 3. Control Plan Construction and Content: Operation, characteristic, specification/tolerance, evaluation or measurement method, sample size/frequency, control method, and reaction plan.

Module 4. Control Plan Phases: Prototype, Pre-Launch, Production, and Safe Launch; objective of each phase, reinforced controls, and criteria for reducing additional controls.

Module 5. Control Selection and Reaction Plans: Prevention, detection, error proofing, process parameters, inspection/SPC, suspect product, containment, and escalation.

Module 6. Highly Automated Manufacturing: Sensors, vision systems, interlocks, poka-yoke, automated measurement, contingency plans for bypass/failures, and evidence of effectiveness.

Module 7. Digital Management, Maintenance, and Changes: Software utilization, version control, approvals, and update triggers due to changes, quality issues, PFMEA actions, or CSR.

Module 8. Shop-Floor Verification and Core Tools Integration: Coherence across Flowchart – PFMEA – Control Plan – Work Instructions – Records; impact on MSA, SPC, and PPAP evidence.

Module 9. Practical Workshop and Assessment: Development/review of an automotive Control Plan, gap identification, definition of controls, Safe Launch, and reaction plans.