Control Phase – Introduction to the Lean Six Sigma Control Phase

Welcome to the Lean Six Sigma Control Phase

The L6S DMAIC Control Phase

4.3

Improve – Put changes into place that eliminate the root cause of problems

Lean Six Sigma – 06 – Control Phase

With improvements in place and the process problem fixed, the team must work to maintain the gains and make it easy to update best practices. In the Control Phase, the team develops a Monitoring Plan to track the success of the updated process and crafts a Response Plan in case there is a dip in performance. Once in place, the Process Owner monitors and continually updates the current best method

  • Statistical Process Control (SPC)
  • Process Control Charts
  • Discrete and Continuous Data
  • Individual and moving range (I-MR)
  • XBar-R chart and Xbar-S charts
  • Poisson Distribution
  • P-Chart and the Np-Chart
  • The U-Chart and the C-Chart
  • CUMSUM/CUSUM control chart
  • The Process Control Plan
  • Closing the DMAIC Project
  • ... and much much more

This course comprises the following modules:

  1. 1
    This is the first of two modules looking at Statistical Process Control (SPC). I first describe the purpose of the DMAIC Control Phase and remind you of the process model X’s and Y’s. I describe the SPC purpose, and the use of control charts as a powerful monitoring and control tool.  
  2. 2
    This is the second of two modules looking at Statistical Process Control. In this second module you and I continue looking at control charts and their use in unearthing process variations. We examine the differences between common and special cause variations and how the control chart identifies them for you.
  3. 3
    In this Module, you and I deep dive into two different Control Chart Limits – control limits and specification limits. You will learn how they are applied to the normal distribution model, and how both control and specification limits are used and applied. I finish up by illustrating three example applications.
  4. 4
    Here, I describe Continuous Control Charts, and first I explain the differences between discrete and continuous data, going on to differentiate between actual and assumed causation.   I take you through the application and use of control charts and the definition of Rational Subgroups.
  5. 5
    This is the first of several models discovering the many variations of control charts used for different purposes. Here, I describe the Individual and Moving Range (I-MR) and both the XBar-R chart and Xbar-S chart uses. You will learn why all these charts have twin views and how these provide powerful process control analysis.
  6. 6
    Module 6. Here, I introduce the concept of attribute charts and discuss the binomial distribution to describe Event Probabilities. You and I clarify the differences between the terms Defects and Defective, going onto examine the Poisson Distribution. I introduce the family of Attribute chart types and their application to Attribute/Discrete data.
  7. 7
    Here, I take you through both the P-Chart and its variant the Np-Chart for proportions and binomial distribution. I describe examples for each, going on to show how the Np Chart is used to plot defectives.
  8. 8
    You and I examine three More Charts, the U-Chart, the C-Chart, and the Exponentially Weighted Moving Average (EWMA) Chart. These plot the average number of defects, the constant sample size for defects, and the faster defect identification of EWMA.
  9. 9
    In this, the final module on control charts, I describe the use and application of the CUMSUM/CUSUM control chart. The acronym standards for cumulative sum and is a powerful technique for unearthing otherwise unknown small shifts in mean and out-of-control situations. I provide a detailed example to clarify the process.
  10. 10
    This is the first of two modules looking at the Process Control Plan and its purpose in sustaining benefits. I take you through the structure of the process control plan and the parameters it must control. I take you through the control mechanisms themselves, the all-important Reaction Plan section, and the steps in implementing the control plan itself.
  11. 11
    This is the second and final module on the Process Control Plan, and here we look at an example control plan template. I guide you through various sections with a simple example. I round this module up with a tour of the two-sample T-test, the Chi Square test, and Box Plots and show how they are used as tools for improvement.
  12. 12
    In this, the final module within the DMAIC Control Phase, I show you the steps in closing your DMAIC project. We cover handover to the process owner, benefit realization, documentation archiving, and official sign-off.
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