What is the Lean Six Sigma Control Plan?

A Control Plan is a way of documenting the quality control functional aspects that will be executed to ensure that quality requirements are satisfied for a specific product or service. The control plan’s goal is to codify and describe the control system that will be used.

Cutting and eliminating superfluous stages and waste in a process or business model is one of Lean Six Sigma’s major goals. Any phase that adds no value to the process is eliminated using the Lean methodology, which helps to improve efficiency, workflow, and profitability.

What is the purpose behind the control plan?

Organizations build control plans to enable business leaders to monitor metrics, document successes, and make modifications for continuous process improvement in order to improve quality. A control plan is a way of documenting the quality control functional aspects that will be executed to ensure that quality requirements are satisfied for a specific product or service.

The control plan’s goal is to ensure that the project team’s performance gains are maintained throughout time. During the DMAIC Control phase, you will create and implement a control plan. It’s a written summary of what’s required to keep an improved process operating at the desired level. This comprises steps to take if measurements fall outside of the intended range, as well as reactions to guarantee that process owners maintain the gains.

In general, the control plan will show a better process map, important process variables, and the reaction plan in the event that the improved process begins to degrade.

How does the six sigma control plan work?

The Six Sigma Control Plan phase identifies where there are lags or faults in the manufacturing process and lays out how an organisation will respond to these lags, whether by corrective action, revising a product, or scrapping a product.

A control plan is a living document that specifies the procedures used to ensure the quality of important inputs in order to produce outputs that meet client expectations. It also includes a documented explanation of the measurements, inspections, and checks used to ensure that production parts and processes are in good working order.

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Who develops the Lean Six Sigma Control Plan?

A control plan should be developed by a designated team and the process owner to improve service quality. The plan should be changed over time based on evaluations conducted after its implementation.

Because earlier attempts to improve quality and business performance consistently revealed that process behaviour is complicated and fragile and that hard-won gains can be lost if the process is left to its own devices, Six Sigma places a premium on the Control phase and planning for it. A system of events, actions, and feedback loops is referred to as a process.

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During the Six Sigma control phase, your actions in building a control plane — and the knowledge you receive from it — almost guarantee that the increased performance you’ve worked so hard to attain will last. Developing process controls before Six Sigma was something akin to trying to boil the seas.

Why is a control plan important?

Regardless of the importance of the process, organisations would frequently go to great lengths to establish a comprehensive plan for every process and every element of every process. It was like attempting to eat an elephant in one mouthful! Six Sigma, on the other hand, allows you to identify the most essential processes and the input and output variables that matter the most.

The control effort shifts from a broad-swathed flashlight to a concentrated laser beam as a result of this prioritising. Creating a control plane for a Six Sigma project is not only a much easier option, but it is also a must-do task.

What are the attributes of the six sigma control plan?

• One of Lean Six Sigma’s main goals is to eliminate unnecessary phases and waste in a process or business model. The Lean methodology aims to enhance efficiency, workflow, and profitability by eliminating any phase that adds no value to the operation.
• Organizations create control plans to allow business leaders to track metrics, document successes, and make changes to improve quality through continuous process improvement. A control plan is a technique of outlining the quality control functional components that will be implemented to ensure that a product’s or service’s quality standards are met.
• A control plan can aid in the improvement of process performance by establishing error-proofing strategies that aim to remove errors in the process whenever possible. Poka-yoke, which literally means “to avoid errors,” is a common Six Sigma waste-reduction strategy.
• Performance Reporting and Sampling — A control plan can also help with determining when and how often to do performance management reviews, as well as what products or services to inspect for mistakes. A well-organized control plan answers all questions and aids organisations in determining the efficiency of their processes.
• Remedial Actions – Corrective measures are taken in response to problems that have been identified and usually result in the system being modified or individual problems being fixed to prevent a recurrence. Production delays and other preventable issues must be avoided by taking timely remedial steps.
• Strategy for a Control Plan – Successful Six Sigma control plans are built on well-thought-out tactics that reduce the need for process tampering. They assemble the measures that must be taken in order to deal with out-of-control situations.

Conclusion

The roadmap for Lean Six Sigma process improvement comes to a close with this stage. Control is defined as Define-Measure-Analyze-Improve-Control (DMAIC). Creating a control strategy is one part of the control.

The negative business impact of process deterioration can be avoided with a well-designed control strategy in place. When performance measures are not within a targeted range, a control plan can include procedures that must be implemented quickly. Process owners must assume ownership of the execution of a control plan for their sector of business, which requires an organisational system.

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