Why might control be considered the most important step in the six sigma process?
The final phase of a DMAIC Project!The CONTROL phase is the conclusion of the team's journey. The GB/BB is responsible for a solid hand-off to the Process Owner to maintain the gains. Show
The final capability is determined and the closing performance and all related changes are documented on the closing contract. This phase is not as statistically intensive as the MEASURE, ANALYZE, and IMPROVE phases. Rewarding the team and stakeholders is important because they not only deserve it but to leave on a final positive note and grow credibility for the GB/BB and the company's Six Sigma program. There can not be enough emphasis placed on the importance of devoting the same high level of
energy and commitment throughout this phase. Complacency and anxiety can set in for the sake of bringing closure receiving credit for executing a project. This can result in the process reverting to the former performance levels and loss of some or all of the gains. In addition, the Six Sigma program and the GB/BB lose credibility. One of the most common complaints of a Six Sigma program is that is a "flavor of the month" or "common sense stuff". Rigorous follow-up and corrective action with comprehensive documentation can increase the likelihood that the gains are sustained. The number one killer for your reputation as a GB/BB and the overall company's program is when a process reverts back to the original performance...do not allow that to happen. The GB/BB should also make recommendations to upper management or a MBB for future project recommendations to further improve process performance. These can lead to new Six Sigma projects or Kaizen Events. Present some interesting findings and improvements that stemmed from the findings. Below
are a list of tools commonly used in this phase.
Assessing Final Process Capability Process Yield Metrics FY - Final Yield TPY - Throughput Yield RTY - Rolled Throughput Yield NY - Normalized Yield Z-scores Other Tools Visual Management Recalculating Control LimitsOnce the improvements are complete it may be warranted to calculate new process control limits and make these limits the triggers for corrective and preventive action. If the three questions below can be answered YES then recalculate the control limits of the process and use them on the SPC charts and document them on the Control Plan for future monitoring.
If you can not answer YES to all of the above criteria then the Process Owner should have information in the Control Plan that identifies corrective action and ideas for the special causes (assignable causes). The process is probably not mature, or in enough control, to use recalculated control limits. Process control should be done before assessing final process capability. Templates, Tables, and Calculators Six Sigma Certification programs Subscribe to access entire site Search Six Sigma related job postings Return to the Six-Sigma-Material Home Page What is a Six Sigma Control Plan?A Lean Six Sigma control planWhat is a Six Sigma Control Plan and how does it work? The L... is a detailed written description of the processThere are many ways to organize your lean six sigma processe... Learn More.... It outlines the steps that must be taken to keep a process or device running at its current levelStatistics level A statistics level is the value of input in... of performance. Control plans provide a detailed description of each step and the parameters that must be monitored to avoid deviations or variations from the mean performance of a batch of products. A Lean Six SigmaSix Sigma Definition: Six Sigma is a set of techniques and t... Learn More... control planWhat is a Six Sigma Control Plan and how does it work? The L... consists of two segments
The Process Management SummaryThe process management summary is used to gather all critical-to-quality outputs (or CTQs) for a process or department, division, or entire company. The summary can be rolled up to any level required by your company for monitoring, reviewing, and taking actions to ensure acceptable business performance and process quality. Add the LeanLEAN Definition LEAN is a production method aimed primarily ... Learn More... Six SigmaSix Sigma Definition: Six Sigma is a set of techniques and t... Learn More... project’s CTQs each time you complete it to your summary. The administrative section of this summary is used to identify the organizational areas that are being discussed, as well as the revision level and the date. The main body is where the summary’s purpose is captured. It provides enough information to allow anyone to easily see the status and how they relate to downstream processes. The Process Control PlanThe process control plan serves as a companion to the process management summary. The process control plan helps you to concentrate on the Xs, the inputs to your process. The inputs are defined in the formula Y = f(x). These are the crucial Xs determined by the Lean Six Sigma project. You can also place the (CTQs) on a process control programWhat is a Six Sigma Control Plan and how does it work? The L.... The process control plan, when done properly, creates a complete picture that includes all inputs, outputs, and activities for a single process. What’s the purpose of a Six Sigma Control Plan and how can it help you? The purpose of the control phase of the DMAICDMAIC is an abbreviation of the five improvement steps it co... roadmap is to ensure that performance improvements made by the project group are sustained over time. A Control Plan is basically a summary of all information pertinent to control the improved process. Why use a Control Plan?A Lean Six Sigma Control Plan is a single reference point for understanding the process’s characteristics, specifications, and standard operating procedures (or SOPs) for the process. The Control Plan can be used to assign responsibility and allocate accountability for each activity in the process. This allows for smooth execution and long-term sustainability. A well-designed control plan can help the business avoid negative business effects from process flaws or process deterioration. It also helps product and process owners track and correct the performance of Key Performance Input Variables (KPIVs) and Key Performance Output Variables (KPOVs). What to know before developing the Control PlanLean Six Sigma Control Plans are crucial to decision-making and should be prepared after careful consideration and assessment of the project’s product status from all angles. These attributes must be considered before the project can begin.
An exampleHow to structureA Lean Six Sigma Control Plan can include as many or few items as necessary to meet the requirements of the project or process being considered. The following are some examples of Control Plan items:
In ConclusionThe Lean Six Sigma control plan, when done properly, creates a complete picture that includes all inputs, outputs, and activities for a single process. The control plan is critical to be a focal point for the control of the improved process. Related SSDSI ArticlesWhy is control the most important step in the Six Sigma process?The Control phase ensures the solution is properly implemented, documented, measured and maintained. “It's the stage where you embed the new practice within the organisation,” University of South Australia's Lean Six Sigma lecturer and consultant Dr Neil Davison explains.
What is the main purpose of the control phase?The main objective of the Control phase is to measure the new process characteristic and validate the improvement. Then implement a control plan and response plan to ensure the new process is strictly implemented.
What is the Control plan in Six Sigma?What is A Six Sigma Control Plan? In the world of quality management, a control plan is a written summary of the process that lays out in detail the steps to be taken to maintain a process or a device operating at the current level of performance.
What is the most important step in the Lean Six Sigma methodology?The DMAIC process, a key fundamental of the six sigma methodology, is designed to create efficiencies and improve productivity.
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