Building QA Skills: CPD Log Reflection

Process Control Basics

Phase 1: Knowledge Evidence (The “What” and “Why”)

In this section, you will document your understanding of how process control functions as the “heartbeat” of UK manufacturing and service sectors.

1. Defining Process Control in QA

Process control is the active monitoring and adjustment of a process to ensure it operates predictably and efficiently. In a vocational context, it is the difference between catching a mistake (Quality Control) and preventing it from happening (Quality Assurance).

Key Concept: Maintaining the “Steady State.”
Relevance: It reduces waste, ensures safety, and maintains compliance with UK Health and Safety at Work Act 1974.

2. Techniques and Applications

Vocational excellence requires knowing which tool to use for the job.

Technique	Application	UK Context Example
Statistical Process Control (SPC)	Using Control Charts to track variables (e.g., temperature).	Monitoring oven temperatures in a commercial food production line.
Total Quality Management (TQM)	A company-wide approach where every worker is responsible for quality.	Used in UK automotive assembly to empower line workers to stop production if a fault is found.
Lean/Six Sigma	Focuses on removing “Muda” (waste) and reducing variation.	Streamlining NHS patient processing to reduce wait times and errors.

Phase 2: Competency & Compliance (The “How”)

To meet Level 2 competency, you must understand the regulatory landscape and the link between control and consistency.

1. Product Consistency

Consistency is the primary goal of process control. If a process is “in control,” the output is predictable. This is vital for meeting The Consumer Protection Act 1987, which holds UK producers liable for damage caused by defective products.

2. Monitoring and Controlling Processes

Effective monitoring involves three steps:

Measurement: Using calibrated sensors or manual checks.
Comparison: Checking data against established SOPs (Standard Operating Procedures).
Adjustment: Taking corrective action (e.g., tightening a valve or recalibrating a machine) before the product falls out of specification.

UK Regulation Note: All process control records must be kept in accordance with The Data Protection Act 2018 (UK GDPR) if they contain identifiable personnel data, and must be accessible for audits by bodies such as ISO 9001 auditors.

Phase 3: CPD Log & Future Learning Plan

Complete the following log as part of your vocational evidence folder.

Part A: New Knowledge Gained

What did I learn today? (e.g., I learned how to interpret a Control Chart and identify “Out of Control” trends.)
How does this support my current role? (e.g., I can now identify when a machine is failing before it produces scrap metal, saving the company money.)

Part B: Future Learning Plan

Identified Gap: I need to understand the specific calibration requirements for the measuring tools used in my department.
Proposed Activity: Attend a workshop on UKAS (United Kingdom Accreditation Service) standards for instrument calibration.
Target Date: [Insert Date]
Objective: To ensure that the “Monitoring” phase of my process control is scientifically accurate and legally defensible.

Assessment Checklist for Learner

[ ] Did I define process control without using overly academic jargon?
[ ] Have I linked my monitoring techniques to specific UK regulations?
[ ] Is my CPD log reflective of my actual daily work environment?
[ ] Have I identified a clear, actionable goal for my next qualification level?