Six Sigma Control Plans

2001 ConceptFlow

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

2001 ConceptFlow

Why Learn About Control Plans?

Six Sigma Control Plans become Institutional memory Focus for operational excellence First step in process control Aids for timely process repair Aids for timely process change Training tools Customer audit tools

2001 ConceptFlow

What is a Six sigma Control Plan?

The Six Sigma Control Plan is a set of 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

2001 ConceptFlow

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 last years yard cleaning service for dog owners. You demand a plan from them.

2001 ConceptFlow

Class Exercise Task

Make a list of things your children will have to do to keep in control so they will have a successful summer of repeat business, as well as guarantee no damage or mess to your yard.
Who?

What?

When?

Why?

How?

2001 ConceptFlow

Control Plan Building Blocks

Sustaining the Improve Phase gains requires an institutional discipline that includes Six Sigma Process Control Plans Six Sigma Measurement Control Plans Six Sigma Operating Procedures

2001 ConceptFlow

Six Sigma Process Control Plan

2001 ConceptFlow

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

2001 ConceptFlow

Six Sigma Process Control Plan Sample Form

Six Sigma Process Control Plan
Process Name: Customer Location: Area: Int/Ext Prepared by: Approved by: Approved by: Approved by: Page: Document No: Revision Date: Supercedes: of

Sub Process

Sub Process Step

CTQ KPOV KPIV

Specification Characteristic

Specification/ Requirement USL LSL

Measurement Method

Sample Size

Frequency

Who Where Measures Recorded

Decision Rule/ Corrective Action

SOP Reference

Control Plan

2001 ConceptFlow

Six sigma Control Plan Administrative

Invoicing Example
Six Sigma Process Control Plan
Process Name: Invoice to Order Reconciliation Customer Location: Area: All Commercial Corporate Accounts Processing Invoicing Int/Ext Ext Prepared by: Approved by: Approved by: Approved by: J Blackbelt J Accounts Mgr J Marketing Mgr J VIP Page: 1 of 2 Document No: BP-CP-00-321 Revision Date: 6/12/05 Supercedes: New

2001 ConceptFlow

10

Process Area

Six Sigma Process Control Plan

Process Name: Bottling Customer Location: Area: Packaging Cherry Hill Soda Plant Line 3 Int/Ext Int

The process area information should uniquely identify the specific location of the process

2001 ConceptFlow

11

Approvals

Six Sigma Process Control Plan

Prepared by: Approved by: Approved by: Approved by: J Blackbelt J Accounts Mgr J Marketing Mgr J VIP

The Black Belt and managers of the affected areas should all approve the Control Plan

2001 ConceptFlow

12

Document Numbers and Revision Maintenance

Business Process
Managing documentation and changes 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

Document No: BP-CP-00-321 Revision Date: 6/12/05 Supercedes: New

2001 ConceptFlow

13

Six Sigma Process Control Plan Substantive

Order Entry Example

Sub Process Sub Process Step CTQ KPOV KPIV Specification Characteristic Specification/ Requirement USL LSL Measurement Method Sample Size Frequency Who Where Measures Recorded Decision Rule/ Corrective Action SOP Reference

Order entry Order entry

Line item check Special pricing agreement x

ordered x price = extended Ord # includes SPA #

no difference SPA field not blank

SAP field Check visual

every line item /order 1 / order

every order every order

SAP CSR

Order Auto E-mail CSR entrty DB CSR Hold order Auto Edatabase mail CSR

BP-OP-03-127 BP-OP-01-173

2001 ConceptFlow

14

Six Sigma Process Control Plan Substantive Sub Process

Sub Process

Sub Process Step

CTQ KPOV KPIV

Order entry Order entry

Line item check Special pricing agreement x

List process area and step of the process being controlled KPOV is directly affecting customer KPIV must be directly linked to a KPOV

2001 ConceptFlow

15

Six Sigma Process Control Plan Substantive Specification

Specification Characteristic Specification/ Requirement USL LSL

ordered x price = extended Ord # includes SPA #

no difference SPA field not blank

Clearly show what is being checked List inspection criteria Spec limits if applicable Attribute screen if applicable

2001 ConceptFlow

16

Six Sigma Process Control Plan Substantive Measurements

Measurement Method Who Measures

Sample Size

Frequency

SAP field Check visual

every line item /order 1 / order

every order every order

SAP CSR

List measurement procedure Resources for control are largely Sample size Frequency Personnel utilization

2001 ConceptFlow

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Six Sigma Process Control Plan Substantive Decision and Reference

Decision Rule/ Corrective Action

SOP Reference

Auto E-mail CSR Hold order Auto Email CSR

BP-OP-03-127 BP-OP-01-173

What to do if measurement shows non-compliance Include process shut down if needed Show linkage to support documents

2001 ConceptFlow

18

Notes on Six Sigma Process Control Plans

Control plans are documents that are used to keep the process running in control Empower local control of process Corrective action authority Corrective action resources Shut down/quarantine authority Must link KPOVs and KPIVs Do not add work to control plans The more work in a Control Plan, the less likely control will be sustained

2001 ConceptFlow

19

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

2001 ConceptFlow

20

Class Exercise Process Control Plan for the Lemonade Stand

Six Sigma Process Control Plan
Process Name: Customer Location: Area: Int/Ext Prepared by: Approved by: Approved by: Approved by: Page: Document No: Revision Date: Supercedes: of

Sub Process

Sub Process Step

CTQ KPOV KPIV

Specification Characteristic

Specification/ Requirement USL LSL

Measurement Method

Sample Size

Frequency

Who Where Measures Recorded

Decision Rule/ Corrective Action

SOP Reference

2001 ConceptFlow

21

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 table use flip charts Discuss potential problems and solutions likely to be encountered Project leaders transfer fields to Six sigma Control Plan Template.xls CP Exercise tab

2001 ConceptFlow

22

Six Sigma Preventative Maintenance Plan

2001 ConceptFlow

23

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

2001 ConceptFlow

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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

2001 ConceptFlow

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Six Sigma Preventative Maintenance Plan Elements

Six Sigma PM Plans contain two sections Administrative Identification Approval Linkage Substantive Failure mode Predictor Actions Responsibility Corrective action

2001 ConceptFlow

26

Six Sigma Preventative Maintenance Plan Sample Form

Six Sigma Preventative Maintenance Plan
Process Name: Customer Location: Area: Int/Ext Prepared by: Approved by: Approved by: Approved by: Page: Document No: Revision Date: Supercedes: of

System

Failure Mode

CTQ KPOV KPIV

Predictor

Predictor Level USL LSL

Measurement Method

Sample Size

Frequency

Who Where Measures Recorded

Decision Rule/ Corrective Action

SOP Reference

PM Plan

2001 ConceptFlow

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Substantive Elements of PM Plan

Elements of a PM Plan are essentially the same as the Process Control Plan Differences are
System Failure Mode CTQ KPOV KPIV Predictor Predictor Level USL LSL

SAP Database

Array Disk Sync

reconcile time

> 30 sec for order database

2001 ConceptFlow

28

Class Preventative Maintenance Plan Exercise

Select two projects from your table Team will help project leaders draft a Six sigma PM Plan Complete two drafts per table use flip charts Discuss potential problems and solutions likely to be encountered Project leaders transfer fields to Six sigma Preventative Maintenance Plan Template.xls PM Exercise tab

2001 ConceptFlow

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Six Sigma Standard Operating Procedures

2001 ConceptFlow

30

Six sigma Operating Procedure Control Plan Focus

Operating Procedure detail will vary from business to business. Focus should contain Description of process Detailed process flow instructions Detailed operation instructions Links to the other control plans Training/skill needs Links to business policies

2001 ConceptFlow

31

Key Learning Points

2001 ConceptFlow

32

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

2001 ConceptFlow

33

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.

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SigmaFlow is a trademark of Compass Partners, Inc. SigmaTRAC is a trademark of DuPont. MINITAB is a trademark of Minitab, Inc.