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CONTROL PHASE, Sigma Level, the median, and the nearest specification…
CONTROL PHASE
Revise Failure Modes and Effect Analysis (FMEA)
Control Plan: track and respond to KPI
Common elements of a control plan include:
Company, division, or department name
• Name of person who created the plan
• Date the plan was created
Name of the person who last edited the plan
• Date the plan was last edited
• Project and/or process name or identifier
• Process owner
List of process steps where control action is required
• CTQ or metric associated with each action required
• Limit specifications, or the acceptable range of measurements
The unit of measurement
• The method of measurement
• The necessary sample size
• The frequency of measurement
The person responsible for measurement
• Where the information is recorded
• Correction actions
• Associated policy and procedure documents
Visual management
SOP visualizations
pictorial instructions
Statistical Process Control Tests: Control Charts
A basic control chart has the following elements:
A line chart of data with plot points for specific data points
An x-bar line representing the average of the data points
Lines above and below the x-bar line representing 1, 2, and 3 standard deviations from the
median in either direction
An upper control limit (UCL) line at 3 standard deviations above the median
A lower control limit (LCL) line at 3 standard deviations below the median
Control Versus Capability
Sigma level is the number of standard deviations between the current process center, as measured by
Process capability is calculated by dividing the sigma level by 3
Control Tollgate Checklist
The team has calculated the performance and capability of the new process
The team has written a control plan and communicated it to the process owner
The team has created a monitor for the process, either through procedures for manual data
collection or automated generation of control charts
The team has provided the process owner and business team with all tools and information
required to maintain improvements
The sponsor, champion, or executive leadership has been informed about the state of the
improvements
The team met to reflect on the project and generate a list of ideas for future improvements
Sigma Level
the median, and the nearest specification limit (not control limit.)