Control Plans
The production control document: characteristics, methods, frequencies, reactions.
View serviceAerospace Quality Engineering & APQP Consulting
Production-ready quality. Engineered for aerospace.
AiroQue Engineering Solutions provides professional Quality Engineering, APQP, process-risk and manufacturing documentation support for aerospace, defense, space and precision manufacturing organizations.
Service index
Twelve services. Each has its own page.
1.0 Position
Your outsourced aerospace Quality Engineering partner.
From Process Flow Diagrams and PFMEA development to Control Plans, inspection plans, work instructions, APQP documentation and production-readiness support, AiroQue helps manufacturers build practical quality controls around their manufacturing processes.
Professional quality engineering support without the cost of a full-time resource — for a single deliverable, a new product introduction, or a defined amount of capacity every month.
2.0 Method
Connecting engineering requirements, manufacturing processes and quality controls.
Quality documentation fails when it is produced as a set of unrelated spreadsheets. AiroQue develops each document as one link in a chain, so a requirement can be traced to a process step, to a risk, to a control, to an inspection, to a reaction — and back again.
01
Engineering requirements
Drawings, models, specifications, contractual and customer requirements.
02
Manufacturing process
The sequence as it actually runs, including outside processing.
03
Process risk
Where the process can produce nonconforming product, and how it would be caught.
04
PFMEA
Failure modes, effects, causes, prevention and detection controls.
05
Control Plan
The controls that carry the risk analysis into daily production.
06
Inspection plan
Characteristics, methods, equipment, sampling, acceptance criteria.
07
Special characteristics
Identified, flowed through the documentation, and controlled.
08
Reaction plans
What happens when the process or the product goes outside limits.
09
Work instructions
The controls, restated in the language of the workstation.
10
Production readiness
Documentation verified as ready to support the process.
3.0 Services
Twelve services, each with its own page
Scope, inputs, deliverable format, starting price and what can be tailored are set out in detail for every service.
Process Flow Diagrams
The manufacturing sequence as it actually runs, end to end.
View servicePFMEA Development
Process risk analysis written against your process, not a template.
View servicePFMEA / Control Plan Alignment
A gap review between the risks you identified and the controls you run.
View serviceAPQP Documentation
Planning and deliverable packages for new product introduction.
View serviceInspection Plans
How each requirement is verified, by what method, how often.
View serviceSpecial Characteristics
Identification, flow-down and control of special, key and critical features.
View serviceReaction Plans
What actually happens when a characteristic goes out of limits.
View serviceWork Instructions (SWI / VWI)
Documentation written to be used at the workstation.
View serviceEngineering Change Impact
Which documents a revision affects, identified before it bites.
View serviceProduction Readiness
Whether the documentation is ready to support the first production run.
View serviceQuality-System Documentation
Procedures, forms, records and change control for aerospace quality systems.
View service4.0 Tailoring
No two customers receive the same document.
Format, column structure, classification symbols, numbering conventions, reading level and terminology are set by your customer requirements and your plant — not by an AiroQue house template.
A Control Plan for a machined detail submitted to one prime looks nothing like a pass-through inspection plan for a distributed assembly. Both are Control Plans. Both are correct. The difference is who reads them and what they are required to prove.
Their template
Customer-mandated forms are used from the start rather than reformatted at the end of the job.
Their definitions
Special-characteristic symbols, rating scales and designation rules are applied as your requirements define them.
Your numbering
Operation, characteristic and document numbering match your router, records and document control.
Your vocabulary
Cells, tools, stations and forms are named the way your people already name them.
5.0 Differentiators
Why manufacturers choose AiroQue
Aerospace-focused
Documentation designed around aerospace manufacturing environments — special processes, configuration control, flow-down requirements and customer-specific formats.
Integrated documentation
Process Flow, PFMEA, Control Plans, inspection plans and work instructions developed as connected documents rather than isolated spreadsheets.
Practical manufacturing focus
Written to be usable by Quality, Manufacturing Engineering, Inspection, Production and operators — at the desk and at the workstation.
Flexible capacity
Use AiroQue when your internal Quality Engineering team needs additional capacity without adding another full-time employee.
Competitive pricing
Professional engineering support at rates designed as a practical alternative to full-time staffing or large consulting firms.
Change-ready
Documentation updated as engineering requirements, processes, specifications and customer requirements change.
6.0 Engagement
From process requirements to production readiness
Each step produces something the next step depends on, and you hold the review and release points.
Requirements review
Drawings, models, specifications, customer requirements and quality-system requirements you supply.
Process understanding
The manufacturing sequence as it actually runs, including special processes and outside processing.
Risk analysis
Failure modes, effects, causes, and the prevention and detection controls that apply to them.
Documentation development
Process Flow, PFMEA, Control Plan, inspection plan and work instructions, drafted in your format.
Cross-document alignment
Every risk traced to a control, every characteristic traced to a method and a reaction.
Customer review
Draft package reviewed with your Quality and Manufacturing Engineering teams; comments incorporated.
Final controlled deliverables
Released files with revision identification, ready for your document-control system.
Ongoing revision support
Updates driven by engineering change, process change, customer requirements or production issues.
7.0 Credibility
Built around aerospace quality principles
Services are developed with consideration of applicable aerospace quality standards, customer requirements, engineering requirements and contractual requirements.
| AS9100Aviation, space and defense QMS requirements | Documentation, process control, risk and change-management support |
| AS9145Aerospace APQP and PPAP | Planning phases, Process Flow, PFMEA and Control Plan deliverables |
| AS9103Variation management of key characteristics | Key-characteristic identification, monitoring and capability considerations |
| APQPAdvanced product quality planning | New product introduction and production-readiness documentation |
| PFMEAProcess failure mode and effects analysis | Structured manufacturing process risk analysis and revision |
| Special characteristicsSpecial, key and critical features | Identification, flow-down and control per customer requirements |
| Configuration and change managementEngineering and process change | Change impact review and revision of affected documents |
AiroQue develops documentation and provides implementation support. AiroQue does not perform third-party certification and does not certify organizations to AS9100.
Standards, customer requirements and contractual requirements applicable to your program are supplied by the customer and applied to the work. AiroQue does not distribute copyrighted standards.
8.0 Industries
Manufacturing environments we support
Aerospace
Commercial, business and rotorcraft supply chains.
Defense
Defense primes and their supplier base.
Space
Launch, satellite and space hardware programs.
Precision machining
CNC milling, turning and multi-axis work.
Electromechanical
Assemblies combining machining, wiring and test.
Sheet metal
Forming, fabrication, welding and finishing.
Composites
Layup, cure, bonding, trim and inspection.
Aerospace assembly
Mechanical assembly, integration and test.
Need quality engineering capacity?
Whether it is a single Control Plan, a PFMEA and Control Plan brought into alignment, or ongoing monthly support, send the scope and AiroQue will respond with a fixed price and a schedule.