4-5 Control Plans.ppt

8/14/2019 4-5 Control Plans.ppt

1/35

2001 ConceptFlow 0

Six SigmaControl Plans


2/35

2001 ConceptFlow 1

Module Objectives

By the end of this module, the participant will: Understand basic control plan elements

Know the information needed for each field of the elements

Understand the need for documentation management

Write a control plan for each element

Write starter control plan elements for her or his project


3/35


4/35

2001 ConceptFlow 3

What is a Six sigma Control Plan?

The Six Sigma Control Plan is a setof documents that Is a point of reference among characteristics, specifications and

instructions

Links CTQs to the operational details of the process

Encompasses several process areas

Operating procedures

Preventative maintenance

Measurement System (Operational Definitions)

Is dynamic


5/35

2001 ConceptFlow 4

Class Exercise Background

The Lemonade Stand Your house is situated near the 9th hole of a popular golf course.

Looking for a way to make some spending money your son and

daughter decide that they are going to sell super lemonade drink from

your yard to the golfers as they head out to the back nine.

Before you will allow them to set up shop, you remind them of their lastyears yard cleaning service for dog owners. You demand a plan from

them.


6/35

2001 ConceptFlow 5

Class Exercise Task

Make a list of things your children will have to do to keep in control sothey will have a successful summer of repeat business, as well as

guarantee no damage or mess to your yard.

Who?

What?

When?

Why?

How?


7/35 2001 ConceptFlow 6

Control Plan Building Blocks

Sustaining the Improve Phase gains requires an institutional disciplinethat includes

Six Sigma Process Control Plans

Six Sigma Measurement Control Plans

Six Sigma Operating Procedures



Six Sigma Process Control Plan



Six Sigma Process Control Plan Elements

Six Sigma Process Control Plans contain two sections Administrative

Identification

Approval

Linkage

Substantive

KPVs being controlled

Specifications

Methods

Responsibility Corrective action



Six Sigma Process Control PlanSample Form

ControlPlan

Prepared by: Page: of

Approved by: Document No:

Location: Approved by: Revision Date:

Area: Approved by: Supercedes:

KPOV KPIV

Measurement

Method

Who

MeasuresSub Process

Sub Process

Step

Specification

Characteristic

Specification/

Requirement

USL LSL

CTQSample Size Frequency

Where

RecordedSOP Reference

Decision Rule/

Corrective Action


Customer

Process Name:

Int/Ext
http://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xls



Six sigma Control PlanAdministrative

Invoicing Example

Prepared by: Page: of 2

Ext Approved by: Document No:



1

BP-CP-00-321

New

6/12/05

Process Name:

Int/Ext


Customer

J Blackbelt

J Accounts Mgr

J Marketing Mgr

J VIP

Invoice to Order Reconciliation

All Commercial

Corporate Accounts Processing

Invoicing



Process Area

Int

Location:

Area: Line 3

Bottling

Packaging

Cherry Hill Soda Plant


Customer

Process Name:

Int/Ext

The process area informationshould uniquely identify the

specific location of the process



Approvals

Prepared by:

Approved by:

Approved by:

Approved by:

J Blackbelt

J Accounts Mgr

J Marketing Mgr

J VIP

The Black Belt and managers ofthe affected areas should all

approve the Control Plan



14/35

2001 ConceptFlow 13

Document Numbers and RevisionMaintenance

Managing documentation andchanges is challenging for a lot of

organizations

The management of documentation

and changes is a key element to

sustaining the gains of six sigma

Page: of 2

Document No:

Revision Date:

Supercedes:

1

BP-CP-00-321

New

6/12/05

Business Process


15/35

2001 ConceptFlow 14

Six Sigma Process Control PlanSubstantive

KPOV KPIV

x

x

SAP field

Check

every line

item /orderevery order SAPOrder entry Line item check

ordered x price

= extendedno difference

Order

entrty DBAuto E-mail CSR BP-OP-03-127

Where


Decision Rule/

Corrective Action

Order entrySpecial pricing

agreement

Ord # includes

SPA #

SPA field not

blankvisual 1 / order every order CSR

CSR

database

Hold order Auto E-

mail CSRBP-OP-01-173

Sample Size FrequencyMeasurement

Method

Who

MeasuresSub Process

Sub Process

Step

Specification

Characteristic

Specification/

Requirement

USL LSL

CTQ

Order Entry Example


16/35

2001 ConceptFlow 15

Six Sigma Process Control PlanSubstantiveSub Process

List process area and step of the process being controlled

KPOV is directly affecting customer

KPIV must be directly linked to a KPOV

KPOV KPIV

x

x

Sub ProcessSub Process

Step

CTQ

Order entrySpecial pricing

agreement

Order entry Line item check


17/35

2001 ConceptFlow 16

Six Sigma Process Control PlanSubstantiveSpecification

Clearly show what is being checked

List inspection criteria Spec limits if applicable

Attribute screen if applicable

ordered x price

= extendedno difference

Ord # includes

SPA #

SPA field not

blank

Specification

Characteristic

Specification/Requirement

USL LSL


18/35

2001 ConceptFlow 17

Six Sigma Process Control PlanSubstantiveMeasurements

List measurement procedure

Resources for control are largely

Sample size

Frequency Personnel utilization

Measurement

Method

Who

MeasuresSample Size Frequency

visual 1 / order every order CSR

SAP field

Check

every line

item /orderevery order SAP


19/35

2001 ConceptFlow 18

Six Sigma Process Control PlanSubstantiveDecision and Reference

What to do if measurement shows non-compliance

Include process shut down if needed

Show linkage to support documents

Hold order Auto E-

mail CSRBP-OP-01-173

Auto E-mail CSR BP-OP-03-127

SOP ReferenceDecision Rule/

Corrective Action


20/35


21/35

2001 ConceptFlow 20

Class Exercise

The Lemonade Stand More information

1. You only make weekly trips to grocery

2. The blender needs rinsing after every use

3. The knife needs sharpening every 50 lemons

4. 10 customers are break even

5. More than 100 customers cannot be handled

6. Stand must be attended when customers come

7. Golfers in this area carry big bills


22/35

2001 ConceptFlow 21

Class Exercise Process Control Plan for theLemonade Stand





KPOV KPIV

Measurement

Method

Who

MeasuresSub Process

Sub Process

Step

Specification

Characteristic

Specification/

Requirement

USL LSL


Where


Decision Rule/

Corrective Action


Customer

Process Name:

Int/Ext


23/35

2001 ConceptFlow 22

Class Process Control Plan Exercise

Select two projects from your table Team will help project leaders draft a Six Sigma Process Control Plan

Complete two drafts per tableuse flip charts

Discuss potential problems and solutions likely to be encountered

Project leaders transfer fields to Six sigma Control Plan

Template.xlsCP Exercise tab
http://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xlshttp://d/Six%20Sigma%20Control%20Plan%20Template.xls


24/35

2001 ConceptFlow 23

Six Sigma Preventative Maintenance Plan


25/35

2001 ConceptFlow 24

Preventative Maintenance and Reliability

Preventive Maintenance is a reliability activity Should be linked to CTQs

Keeps process centered

Reduces variation

Not just a repair function

Reduces excursions


26/35

2001 ConceptFlow 25

Preventative Maintenance Focus

Failure The focus of prevention

Predictor

Indicator of potential failure

Predictor levels

Quantitative level for taking action

Action

What is done

Documentation

Written record of action


27/35

2001 ConceptFlow 26

Six Sigma Preventative Maintenance PlanElements

Six Sigma PM Plans contain two sections Administrative

Identification

Approval

Linkage

Substantive

Failure mode

Predictor

Actions

Responsibility Corrective action


28/35

2001 ConceptFlow 27

Six Sigma Preventative Maintenance PlanSample Form

PMPlan





KPOV KPIV

Measurement

Method

Who

MeasuresSystem Failure Mode Predictor

Predictor Level

USL LSL


Where


Decision Rule/

Corrective Action

Six Sigma Preventative Maintenance Plan

Customer

Process Name:

Int/Ext
http://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xls


29/35

2001 ConceptFlow 28

Substantive Elements of PM Plan

Elements of a PM Plan are essentially the same as the ProcessControl Plan

Differences are

KPOV KPIV

xSAP

Database

Array Disk

Syncreconcile time

> 30 sec for

order database

System Failure Mode Predictor Predictor Level

USL LSL

CTQ


30/35

2001 ConceptFlow 29

Class Preventative Maintenance PlanExercise

Select two projects from your table Team will help project leaders draft a Six sigma PM Plan

Complete two drafts per tableuse flip charts

Discuss potential problems and solutions likely to be encountered

Project leaders transfer fields to Six sigma Preventative

Maintenance Plan Template.xlsPM Exercise tab
http://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xlshttp://d/Six%20Sigma%20Preventative%20Maintenance%20Plan%20Template.xls


31/35

2001 ConceptFlow 30

Six Sigma Standard Operating Procedures


32/35

2001 ConceptFlow 31

Six sigma Operating Procedure Control PlanFocus

Operating Procedure detail will vary from business to business. Focusshould contain

Description of process

Detailed process flow instructions

Detailed operation instructions

Links to the other control plans Training/skill needs

Links to business policies


33/35

2001 ConceptFlow 32

Key Learning Points


34/35

2001 ConceptFlow 33

Objectives Review

By the end of this module, the participant will: Understand basic control plan elements

Know the information needed for each field of the elements

Understand the need for documentation management

Write a control plan for each element

Write starter control plan elements for her or his project


35/35

Trademarks and Service Marks

Six Sigma is a federally registered trademark of Motorola, Inc.

Breakthrough Strategy is a federally registered trademark of Six Sigma Academy.

ESSENTEQ is a trademark of Six Sigma Academy.

METREQ is a trademark of Six Sigma Academy.

Weaving excellence into the fabric of business is a trademark of Six Sigma Academy.

FASTART is a trademark of Six Sigma Academy.

Breakthrough Design is a trademark of Six Sigma Academy.

Breakthrough Lean is a trademark of Six Sigma Academy.

Design with the Power of Six Sigma is a trademark of Six Sigma Academy.

Legal Lean is a trademark of Six Sigma Academy.

SSA Navigator is a trademark of Six Sigma Academy.

SigmaCALC is a trademark of Six Sigma Academy.

SigmaFlowis a trademark of Compass Partners, Inc.

SigmaTRAC is a trademark of DuPont.

MINITAB is a trademark of Minitab, Inc.

Date post:	04-Jun-2018
Category:	Documents
Upload:	anjo0225
View:	215 times
Download:	0 times

4-5 Control Plans.ppt

Documents