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AI agent for quality control inspectors

Control Plan Review Agent

Keep the control plan matched to the real process and defects.

Quality controlOperations
See how it worksGet access
Control Plan Review Agent: what goes in, what the agent does and what you get

What it does

A control plan that does not reflect the process changes becomes paperwork. This agent compares the plan with changes made to the process and with defect data. It flags steps that are not covered and failure modes that appear in the data without a control. It drafts updates to the plan. After the updates, it compares the new plan with recent defects to confirm every failure mode is covered. The inspector approves the changes. Edge case: a new defect type with no matching line in the plan is added as a new row with a proposed check.

How it works

Follow the arrows from top to bottom. The orange dashed arrow is the loop: when a check fails, the agent goes back and tries again.

Start and resultWhat it doesA check on its own workWaits for your OKGoes back and retries
Yes, continueApprovedYes, continueNoNo 1 STARTS WHEN Process change or monthly review 2 USES A TOOL Read the control plan and the change records 3 USES A TOOL Read recent defect data 4 DOES Compare changes and defects with the plan 5 CHECKS THE RESULT Is every changed step and defect covered? If not: List the gaps. Back to step 2. 6 DOES Draft plan updates 7 YOU APPROVE Inspector approves the updates 8 USES A TOOL Update the control plan 9 DOES Match the new plan to recent defects 10 CHECKS THE RESULT Is every failure mode covered by a control? If not: Add the missing control and recheck. Back tostep 5. 11 RESULT Updated control plan
Read the steps as a list
  1. Process change or monthly review
  2. Read the control plan and the change records
  3. Read recent defect data
  4. Compare changes and defects with the plan
  5. Is every changed step and defect covered?If not: List the gaps. Back to step 2.
  6. Draft plan updates
  7. Inspector approves the updatesThe agent waits here for your OK.
  8. Update the control plan
  9. Match the new plan to recent defects
  10. Is every failure mode covered by a control?If not: Add the missing control and recheck. Back to step 5.
  11. Updated control plan

How it decides

It flags gaps where a changed step or a recent defect has no control, and confirms coverage against the defect list.

  • Flag defects seen more than twice without a control
  • Update the plan within 5 days of a process change
  • Check measurement method and frequency
  • Match every failure mode to a control

Make it yours

Every agent is a starting point. You choose these settings for your own situation.

  • Review frequency
  • Defect count that triggers a flag (default 3)
  • Update deadline
  • Format of the plan

What keeps you in control

It always asks you first

  • Inspector approves plan updates

Hard limits

  • Never edit the control plan without approval
  • Never ignore a repeated defect

It stops when

  • Done: the plan covers all changes and defects
  • Stop: the process is not stable and the team reviews it first

Set it up

We guide you through the set-up, step by step

Members get the full set-up guide for this agent. No technical skills needed: you copy, paste and upload.

10 minto set it up in your AI
5 AIsChatGPT, Claude, Copilot, Gemini, Grok
  • One set of instructions to paste into your AI, with the clicks for ChatGPT, Claude, Microsoft 365 Copilot, Gemini and Grok
  • The agent then walks you through connecting your own data, one source at a time
  • A downloadable copy with the flow chart, the rules and the full guide
Get access to this agent

An example run

What happensA new weld fixture was added in May. The agent finds that the plan has no check for its clamp pressure and that a new defect, undercut, appeared four times without a control. It drafts two new rows. The inspector approves and the agent confirms every failure mode now has a check.

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