Imagine this: During the production of an important batch, output suddenly drops. A quality measurement shows issues, or an unexpected deviation appears in the process. The line stops, operators scramble to find the cause, and every minute costs money. In such moments, it is crucial not to panic, but to act according to a clear plan: the Out of Control Action Plan (OCAP). In this blog, we explain what an OCAP is, why it is important, and how the EZ-GO platform can help in creating and using an Out of Control Action Plan.
What is an OCAP?
An OCAP (Out of Control Action Plan) is a standard procedure that outlines the steps to take when a process goes ‘out of control’. In other words, if a deviation occurs that falls outside established tolerances or limits, a predefined action plan can be followed. The purpose of an OCAP is to enable fast and correct responses by immediately identifying the cause of the deviation. Additionally, an OCAP is designed to bring the process back under control as quickly as possible. Actions such as visual inspection, temporarily stopping the line, performing a control measurement, or notifying the quality department are commonly included to achieve this. In short, an OCAP ensures that everyone knows exactly what to do when something goes wrong in a process.
Why is an OCAP important?
Deviations are inevitable in a production environment. Naturally, machines will experience wear, raw materials may vary, and human errors can occur. However, the way a problem is addressed is far more important than the problem itself. Without an Out of Control Action Plan (OCAP) template outlining the correct steps for each situation, chaos can arise on the shop floor. Too much time may be spent in discussions, decisions may vary each time, or actions may be based on intuition rather than a plan. This increases the risk of production loss and additional costs. A well-prepared OCAP model provides:
- Speed: Operators do not have to think about what to do because the steps are predefined.
- Consistency: Everyone responds the same way to similar deviations, increasing quality and reliability.
- Transparency: All actions are recorded, which supports audits and continuous improvement.
- Risk control: Immediate intervention helps prevent larger errors, waste, or accidents.
What does an Out of Control Action Plan include?
A complete OCAP model contains several components that together ensure the structured approach an OCAP is known for. The most important elements are the FMEA for each factor, the control chart, and risk prioritization.
FMEA for each factor
In an OCAP model, an FMEA (Failure Mode and Effects Analysis) is prepared for every critical process factor. An FMEA identifies potential ways a process can fail, including their effects and possible risks. This clarifies where the greatest risks lie and which causes have the most impact on product quality or safety. An FMEA helps define the procedure for specific deviations, who is responsible for the required actions, and how the process should be restored.
Control chart
A control chart visually maps process performance over time, making it easy to see whether processes remain within pre-set limits. If a measurement falls outside the control limits, the OCAP is triggered. Essentially, the control chart acts as the ‘trigger’ for action, allowing decisions to be based more on facts and less on intuition.
Prioritize risks
Not every deviation requires immediate action. Therefore, it is important to prioritize risks. In an OCAP model, this means defining which deviations are urgent and which can be investigated later. This prioritization is often based on three factors: severity, frequency, and detectability. Key questions include:
- How significant is the impact of the deviation?
- How often does the problem occur?
- How well can the problem be detected in time?
Example of an OCAP
An example of implementing an OCAP in a practical situation could look like this:
In a factory, a filling machine is used, with specific weight limits set.
Situation:
The weight remains below the lower limit, deviating beyond the allowed tolerance.
Action:
The line is stopped, and both the scale and the product components are checked.
Responsible:
Operator
Additional Notes:
Remember to recalibrate the machine if necessary.
Out of Control Action Plan in the EZ-GO platform
Within the EZ-GO platform, operators have direct access via tablets or work phones to the correct procedure as soon as a deviation is detected. The platform allows actions to be visualized by adding photos, videos, and step-by-step instructions. Task assignments can also be easily managed within EZ-GO. By managing OCAPs digitally, the most up-to-date version is always available on the shop floor.
Questions about OCAP? Contact us
Want to know how your organization can better handle process deviations, or curious about how the EZ-GO platform can help digitize and optimize your Out of Control Action Plan? Feel free to contact us! Together, we will find a solution that fits your production environment.