Greenbelt Chapter 16: Control Phase Flashcards
Control
During the control phase, teams build monitors that let them ensure the improved process continues with the expected measurement baselines they set forth.
Revise FMEA
(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.
Create a Control Plan
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
Visual Management
Visual management includes color coding, safety signals, visual representation of how a process should be done; (red tapes and numbering schemes)
SPC Charts
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.)
Control Versus Capability Process
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.
Control Tollgate Checklist
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.