Greenbelt Chapter 16: Control Phase

Question 1

Control

Answer 1

During the control phase, teams build monitors that let them ensure the improved process continues with the expected measurement baselines they set forth.

Question 2

Revise FMEA

Answer 2

(Failure Mode & Effect Analysis- from Measure) is from the measure phase.
-There are 2 reasons to revisit FMEA:
1.) They need to check the risk priority number
calculated for the sol’n implemented.

     2.) Can help identify future projects by looking at the 
          FMEA.

Question 3

Create a Control Plan

Answer 3

A Control Plan is “written control plan” for the process owner:
The control plan is made for the team lead so that
they can control, track, and respond to key
performance indicators.

A control plan should be user-friendly. It should be easy to read, should detail- how to monitor, when to monitor, what range of data is acceptable to monitor, and what range is good, etc.

Each workstation should have a control plan:

• company, division, department name
• name of person who created it
• execution date
• project name
• process owner
• list of process steps and where monitoring should be done
• acceptable range of measurements
• unit of measure
• method of measures
• sample size
• frequency of measurements that should be taken
• associated policy & procedure documents

Question 4

Visual Management

Answer 4

Visual management includes color coding, safety signals, visual representation of how a process should be done; (red tapes and numbering schemes)

Question 5

SPC Charts

Answer 5

SPC charts are also called control charts; they are used to see if a process metric is out of range from what is said in the control plan.

Basic SPC Chart/Control Chart Includes:
-a line chart that graphs continuous data for a data metric.
- an x bar line is made for the average that should be
seen
- SD are shown above and below (+/- 3SD).
-This creates 3 different zones ranging from A,B,C
above x-bar and A,B,C below x bar.

*****READING SPC CHARTS ARE VERY IMPORTANT: Based on the ranges of the recorded data points, you will be able to tell the severity of the problem (major problem, minor problem; efficiency; problem with machines, employees, shifts,etc.)

Question 6

Control Versus Capability Process

Answer 6

Terminology:
Controlled Process- not much variation in the process

Capable Process- the process has control as well as creates satisfactory results for customers needs.

You can calculate a processes capability:

(ucl- x bar)/ SD = sigma level
Cpk = sigma level/ 3
Cpk value conversion on table –> ***sigma level =4

***4 sigma is minimum to keep customer satisfaction and therefore be a capable process.

Question 7

Control Tollgate Checklist

Answer 7

Before finishing the Control Phase, complete this checklist:

• Team has calculated performance and capability of new process (control charts were made, cpk was calculated for process)
• control plan is written
• monitors are written and included in control plan
• team has given control transition to business process owner.
• Owner was given all tools that are needed to maintain the process improvement.
• team reflected on the project and gave suggestions for future improvements.