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Free IATF 16949 Control Plan Template

An AIAG-format control plan template for IATF 16949:2016 Clause 8.3.5.1. Includes all 12 required columns — process number, characteristics, CC/SC classification, measurement technique, sample size and frequency, control method, and reaction plan — with 9 pre-filled example rows. Generated in your browser, no login required.

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Control plan columns included

All 12 AIAG-required control plan columns are pre-labeled in the template:

Process #Process Name / Op DescMachine / Device / ToolChar #Char TypeSpecial Char Class (CC/SC)Spec / ToleranceMeasurement TechniqueSample SizeSample FrequencyControl MethodReaction Plan

How to use this template

  1. Select the plan type — mark whether this is a Prototype, Pre-Launch, or Production control plan. Each triggers different PPAP submission requirements.
  2. Complete the header — enter part number, supplier, customer, and core team names. All approval blocks must be signed before the control plan is released.
  3. Map your process steps — list each operation (Receiving, Machining, Heat Treat, Assembly, Final Inspection, etc.) in process flow order.
  4. Identify and classify characteristics — for each step, list all product and process characteristics. Mark CC or SC where applicable using your customer's symbol conventions.
  5. Define measurement and control — specify the gage, technique, sample size, and frequency for each characteristic. CC characteristics require 100% or SPC Cpk ≥ 1.67.
  6. Write specific reaction plans — a reaction plan must name a specific action (e.g., "Stop production, notify QE, quarantine last 2 hours of production") — not a generic "contact supervisor."
  7. Link to PFMEA and Process Flow — IATF 16949 requires these three documents to be cross-referenced. Characteristic numbers and process step numbers should align across all three.

IATF Note: The control plan must be updated when any process change occurs, after a customer complaint, or following an FMEA revision. The core team must approve all updates and the revision history must be maintained (Clause 8.3.5.1).

What's inside the template

1

Control Plan Header

Plan type (prototype/pre-launch/production), part number/name, supplier, customer, core team, and all approval/date fields

2

Control Plan Matrix (AIAG Format)

9 pre-filled example rows across 12 columns: process #, name, equipment, characteristic number/type, SC classification, spec/tolerance, measurement technique, sample size, frequency, control method, reaction plan

3

Special Characteristics Legend

Definitions for CC (Critical Characteristic), SC (Special Characteristic), and standard characteristics

4

Control Plan Notes

Cpk requirements (≥1.67 for CC, ≥1.33 for SC), MSA requirements, retention period, and update triggers

5

Revision History

Revision, date, author, and change description log

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