Control Phase

Goal or purpose:

• To validate that the project benefits are real.
• To ensure the benefits are sustained for the long term with a control plan.

• To document new work methods and processes to ensure the gains are sustained.
• To periodically verify that the controls remain effective.

Deliverables:

• Control Plan
• Control charts with statistically driven limits.
• A trend chart verifying performance at or better than target for three months.
• A list of poka-yoke (mistake proofing) measures.
• Formal documentation of the new method.
• Reaction plans.
• An updated control plan, work instructions, standard operating procedure and operator instructional aides.

Relevant tools:

• Control plan, statistical process control, gauge control plan, graphical techniques, preventive maintenance, poka-yoke or mistake proofing, process management charts and change management tools.

Questions to be answered:

How are the reductions in defects maintained?

• How is the improved process standardized and institutionalized?
• What can be done to ensure continuity in the event of changes in conditions, customers and technology
• What is the new standard method or process? How was it developed?
• How is the new method documented? Where is the documentation kept? How will employees access it?
• Who owns the process? Who will maintain and update documentation? Who will check to make sure the standard methods or processes are used? How often?
• What will be measured in your plan for process management? How often? By whom? How will the data be displayed? Where will control charts be used? What action will be taken if the measurements are unsatisfactory?
• How will you transfer responsibility for ongoing monitoring to the process owner?
• What organizational systems need to change to support standardization?
• What process controls are being implemented to ensure the organization sustains the gains?
• To date, what progress has been achieved in process capability performance? Has your chart been updated?
• Is there a plan to revisit this process in the future to ensure the new capability level is maintained? What new measurements are in place?

Control Phase 1. A control plan