Six Sigma Control Phase

Control

Objectives: Sustain improvements and ensure that problem does not recur

Tasks: Standardize improvement actions; Document and close the project

Control Plan

A written summary describing the systems used for monitoring and controlling the process or product variation.

Control Plan

It is a document allowing the team to formally document all control methods used to meet project goals.

Monitoring Plans

Response Plans

Training Plans

Documentation Plans

Aligning Systems and Structures

Control Plan Elements

Process Monitoring

is critical to ensure that process improvements are sustained. It supports the process monitoring strategy. This is a documented method for how the process owners should respond to any out of control conditions that may occur in the process

Monitoring Plan

is a data collection plan for checking the ongoing health of the improved process. It lists the measure, the targets for each measure, how each measure will be checked, and who will check the measures.

Response Plan

establishes a threshold or trigger level for each measure in the Monitoring Plan.

Monitoring Plan Map

is a guide to continued monitoring of the process, and the response plan for each of the measures being monitored.

Monitoring Plan Map

is like a strategic blueprint that helps you track whether your project is heading in the right direction. It’s a visual and structured tool that outlines what you’ll monitor, how you’ll measure it, and what actions to take if things go off course.

Checklist

Statistical Process Control

Graphical Analysis

Periodic Status Reports

Process Monitoring Methods

Checklist

Listing of critical process activities needed to complete the process or operation successfully. It is used as real time verification that the critical process step has been completed. Used for standardized, low- throughput processes

Statistical Process Control

Used for highly standardized process

Graphical Analysis

keep statistical data on the output of the process. Analyze to decide where process adjustments are needed. This approach is reactive or “after the fact”. Used for non-standardized, high-throughput processes

Periodic Status Reports

Establish key milestones and deliverables. Review status and issues at defined frequency. Used for non-standardized, low throughput processes

0-1 sigma

Training and awareness

1-3 sigma

Development of SOPs and process audits

2-4 sigma

SPC on Y’s

3-4 sigma

SPC on X’s with special causes are identified and acted upon by fully trained operators and stagg who adhere to the rules

3-5 sigma

Mistake proofing prevents a product/service from passing onto the next step

4-5 sigma

Automated mechanism shuts down the process and prevents further operation until a required action is performed

5-6 sigma

eliminates an error condition OR an automated system monitors the process and automatically adults Critical X’s to correct settings without human intervention to sustain process improvements

Full Automation

Systems that monitor the process and automatically adjust Critical X’s to correct set

Mistake Proofing

using wisdom, ingenuity or serendipity to create devices allowing a 100% defect free step 100% of the time

Poka yoke

Japanese term for mistakeng proofing or to avoid “yokeuro” inadvertent errors “poka”

Simple

Inexpensive

Give prompt feedback

Give prompt action

Focused application

Have the correct people’s input

Hints to help design a Mistake Proofing device

Best

makes it impossible for errors to occur

Better

allows for detection while error is being made

Good

detects defect before it continues to the next operation

Dr. Shewhart of Bell Laboratories

developed a theory of variation that states there are two components to variation: Common cause component, and Special cause component

Control Charts

have been around since the 1920s and came into heavy use during World War II.

control chart

is a time plot of a statistic, such as a sample mean, range, standard deviation, or proportion, with a center line and upper and lower control limits.

process

is considered in statistical control if it has no assignable causes, only natural variation.

Continuous Data Charts

is a set of numbers that can potentially take on any value. also known as variable data

I or Xbar chart

shows changes in the average value of the proces. is a visualization of the longer term variation

mR or R chart

reflects shgort term variation. used with Xbar charts depict the ranges within subgroups of data; the key question: “Is the variation within subgroups consistent?”

Individuals and Moving Range chart

is also for continuous data. it can be used for many transactional applications

Policy Statements

prescribe the way an organization intends to carry out its business within its various functions

Operating Procedures

Describe the established methods for performing and administering tasks

Other Supporting Documents

How the various tasks are to be carried out in detail. Examples include work instruction, production plan, project schedule, user manuals, processcontrol plans.

Process Dashboards

Visual trend charts that display the performance of the process

Time series dashboards

Control Charts

Types of Process Dashboards

Time series dashboards

show trends over time as well as current performance.

Control charts

identify the presence of special cause variation on the

process and provide a trigger for action

New Procedure Audit

provides an easy way to check for adaptation to the new way of doing things once a project is successfully completed. It serves as a reminder for both the process analyst and the process owners.

Visual Management

is the practice of making the workplace visually easy to work in. This includes making it easy to identify units and materials, updating people on the process status, showing how the process works and providing a visible process plan for future steps.