Lean与六西格玛培训第12课：Control Plan

Control Plan,May 2015,Kenny,Operational ExcellencePanyu / China,Overall Approach (DMAIC),Process,X1X2X3.,Y1Y2.,Either operational or transactional, all consists of process,Measure,Process Performance,3. Current process performance,2. Ensure data collected is reliable (Gage capabilities),1. Understand Process, Re-scope if necessary,4. Dig out all possible Causes(Do not jump to solution, then you might miss out the major causes),5. Trim down to most possible causes, and drill down to root causes,C&E Matrix,CRT,Population,Data Collection : Sample,Process,Measure,Analysis,Sample Statistics are used to estimate population attributes,Generating Basic Statistics for Information,Control Phase Learning Objective,Understand the methods that sustain the Gain Establish the one stop Control Plan,Six Sigma Summary,We measuredClearly define the problemDetermine the possible causes for outputsFigure out capability of the process and measurement systemWe analyzedAnalyze the dataRoot cause identificationWe improvedDiscovered y=f(x)OptimizationWe controlled ?,One -TimeImprovement,Total Improvement,Fallback,Total Improvement,One -TimeImprovement,Use of standard proceduresto maintain performance,Time,Improvement,Time,Improvement,Control Well,No Control,Why Control ?,Making the improvement suggestion is only half of the battle In many cases, teams are not empowered to implement the solution. The hand off to an implementation team causes several difficulties: The new folks may not be as familiar with the data, analysis and/or solution and may make compromises that weaken the solution. Narrower agendas override business best practice.,Half of the Battle,Defines the methods, tools, resources, and responsibilities needed to sustain the process improvement and project benefits, independent of the support of the Six Sigma Project team and project leader. MonitoringSPCAcceptance Sampling PlanAudit PlanStandardizationWork InstructionDocumentationStandard Operation ProcedureOthersPoka-Yoke,Process Control Strategy,Putting in One Stop page Control Plan,Key Steps in developing a process control system,Complete an implementation plan.Develop method to control each vital X after new implementation.Develop a data collection plan to confirm that your solution meets your improvement goals. Establish measurements system neededCreate and document a response plan to follow in case process performance falls below established standards Train the Operational Team.Run the new process and collect the data to confirm your solution,Process,KPIV,KPIV,KPIV,KPOV,CTQ,Manage,“Correct”(In-Spec.),Defect-Free!,KPIV,HighLowMediumHigh,Control Plan Evaluation,Standard Operating ProceduresDo they exist?Are they simple and understood?Are they being followed?Are they current?Is operator training performed and documented?Is there a process audit schedule?Are SOPs available at appropriate places within processIs there an SOP review & maintenance process?,Control Plan Evaluation,Maintenance ProceduresHave critical components been identified?Does the schedule specify who, what & when?Where are the manufacturers instructions?Do we have a trouble shooting guide?What are the training requirements for maintenanceIs there a Maintenance review & audit process,The Control Plan,A living document which is used to document all you process control methods. *The control plan is a living document and should be updated to reflect the addition / deletion of controls based on experience gained by producing parts (or providing services).,Decision Rule / Corrective Action What happen when the process is out of control? Who take the action?,Example,Exercise,Brainstorming Write down three actions that you will take to ensure that the gains from your project are permanently sustained. Without your attention, considered the time, resources and