Lean Six Sigma Operational - Delegate Workbook

SSG06101ENUK - CP/Issue 1.1/ September 2008 1 The British Standards Institution 2008
Control Plans
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Learning Objectives
At the end of this section delegates will be able to
understand:
Why we need control plans
What elements make up a control plan
Who contributes to their preparation
How to develop a control plan
When to update the plan
Where the plan should reside
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SSG06101ENUK - CP/Issue 1.1/ September 2008 2 The British Standards Institution 2008
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
DMAIC Improvement Process
Control
Control Critical xs
Monitor ys
Validate Control
Plan
Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
Control
Control Critical xs
Monitor ys
Validate Control
Plan
Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
Control
Control Critical xs
Monitor ys
Validate Control
Plan
Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
Control
Control Critical xs
Monitor ys
Validate Control
Plan
Close Project
1 5 10 15 20
10.2
10.0
9.8
9.6
Upper Control Limit
Lower Control Limit
y
Phase Review
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Why do we Care?
A Control Plan is the key to
sustaining the gains from a Six
Sigma project.
A Control Plan:
Exists to ensure that we
consistently operate our
processes such that product
always meets customer
requirements
Ties together the elements of Six
Sigma improvement activity
Allows Champions and other
stakeholders to have confidence
that the process improvements
made will be robust
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SSG06101ENUK - CP/Issue 1.1/ September 2008 3 The British Standards Institution 2008
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plans
Control Plans are the key to successful
completion of the both the Control Phase of the
DMAIC, and the Six Sigma Project
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plans
Plans are put in place to:
Ensure that project gains are sustained
Enable the transition to Business as Usual
Ensure consistent performance of a process
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Strategy
The intent of an effective Control Plan Strategy is to:
Operate our processes consistently on target with minimum
variation
Minimise process tampering (over-adjustment)
Assure that the process improvements that have been
identified and implemented become institutionalised
Provide for adequate training in all procedures
Include required maintenance schedules
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Inputs
All
Processes
Measurement Systems
Resources that need to be monitored and
controlled
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Elements
Process map steps
Key process output variables, targets & specs
Key and critical process input variables with
appropriate working tolerances and control limits
Important noise variables (uncontrollable inputs)
Short and long term capability analysis results
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Elements
Designated control methods, tools and systems
SPC
Automated Process Control
Checklists
Mistake Proofing systems
Standard Operating Procedures
Workmanship Standards Sampling & Testing
Training Materials
Maintenance Schedules
Reaction Plan and Responsibilities
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Structure
Process: Each key
process step is listed.
Process
Process step Input Output Characteristic LSL Target USL Cp/Cpk/% Date Method GR&R Sample Size Frequency Recorded Containment Adjustment
Response Measures Specification Capability Measurement
Measures: Details of the input
and output characteristics
measured for each process step.
Specification: For each
characteristic measured, the
specification (or tolerance or
target) are noted.
Capability: The historical
capability is noted (if available)
with the date of study.
Measurement: The method of measurement and
historical GR&R results are recorded (if available
see page 42). The data collection plan (sample
size and frequency) and format for recording the
measurement are also detailed.
Response: When an out of specification
result is recorded, the response plan details
how to ensure that no defects will reach the
customer (containment) and how to fix the
process (adjustment).
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Who Should Develop the Plan?
The plan should be developed by the project team
in conjunction with those who will be responsible
for the day to day running of the processes
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Exercise
Using one of your projects identify which six sigma tools could
be used in order to develop a Control Plan.
Output : A list of control methods, with examples using the
control plan format.
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Documentation Package
Control Plan Control Plan
Scope
Customer
Summary
Maps
MeasSys
FMEAs
Capability
BB/GB
SOPs
Training
Maint.
Trouble
Shooting
Reaction
Plans
Control Plan Control Plan
Scope
Customer
Summary
Maps
Meas Sys
FMEAs
Capability
BB/GB
SOPs
Training
Maint
Trouble
Shooting
Reaction
Plans
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Control Plan Review
The plan should be validated and then be subject
to regular review, as part of the overall
management system
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SSG06101ENUK Delegate Slides/Issue 1.1/ Septemberl 2008
Summary
When we have improved our process, and
verified that the improvements generate
significant benefits, we need to ensure that the
gains are sustained
Control Plans, together with other appropriate
tools are used to achieve this
Control Plans should be verified for their
effectiveness before the project is finally closed