D–M–A–I–C

CONTROL PHASE
INTRODUCTION

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 The Funnel Effect – Control Phase

Process Map
30 - 50 Inputs
C&E Matrix and FMEA
10 - 15 Xs
Multi-vari Studies
8 - 10 KPIVs
Hypothesis Testing

Graphical Analysis
4-8 Key KPIVs
Statistical Analysis
3-6 Key KPIVs
DOEs

Control Plan Optimized Process

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 Purpose Of Control Phase

• Implement the improved and optimum process

• Monitor process performance and ensure process
improvements are maintained
• Document project and process improvements
• Document approved control plan encompassing all
documentation necessary to sustain improvements

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 Control Phase Roadmap

STATISTICAL PROCESS CONTROL

CONTROL PLAN AND REACTION PLAN

LONG TERM MSA PLAN

CHANGE CONTROL

TRAINING PLAN; STANDARDIZED

WORK; VISUAL WORK PLACE

5S AND MISTAKE PROOFING

INTEGRATE WITH QUALITY SYSTEM

SUSTAIN EXPECTATIONS
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 Questions to Be Answered

Who is the owner of the control plan?

Who is the Process Owner?
Who is responsible for ensuring process
improvements are monitored and sustained?

What controls were developed to maintain process

improvements?
What vehicle ensures that the controls are followed
at all times?
What controls prevent the process from reverting
back to the original, less than optimum process?

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 Questions to Be Answered

Where in the process, is the data being collected?

What type of data is being collected?
What control charts are used to monitor the
process?
Is the process in control and how can it be verified?

When should the new process be audited?

When will the training schedule be communicated?
When will the control plan, and all supporting
documentation, be completed?
When will the project be completed and transferred
to the Process Owner?

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 Questions to Be Answered

Why will the transfer of the improvements to the

Process Owner be successful?
Why will the change control plan and reaction
plan be successful?

How will training of new process be scheduled?

How will using new process be verified?
How will the new process be transferred from
SM
the Black Belt to the Process Owner?
How will the control plan and change control
plan be maintained?

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 Tools

• Control Plans
• Statistical Process Control
• Gage Control Plan
• Graphical Techniques
• Mistake Proofing
• Preventive Maintenance

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 Control Phase Deliverables – Check List

SM
Black Belt is responsible for delivering the following items at completion of
the Control Phase:
 Week 3 Deliverables summarized and updated  Integrate with existing quality system
 Revised problem statement reflecting an  Cost / benefit analysis of improved
increased understanding of the problem process
 Detailed process map of recommended  Improvement transfer opportunities
optimum process identified
 Completed and approved control plan  Completed project management report
 Control charts verifying process is in control (Gantt chart, timelines, milestones,
 Documentation of project critical path)
 Training schedule outlined  Any red flags with project or
 Completed audit plan to ensure results are implementation of new process and
sustained and process remains in control recommendations to resolve
 Reaction plan completed  Next steps
 Change control plan completed  Signed approval of report out by Project
SM
Champion