Control Plan – Monitoring system – Enhancing Your Business Performance

Objectives

What are control plans, and what is the purpose of control plans
What does it do?
Putting the control plan into place
Control Charts
Integrating control charts and plans

Control and Response plans must be prepared to ensure the following:

Creating and aligning the system, structure, and processes
Complete documentation of the processes and procedures
Developing a monitoring and response plan in case the performance drops
Training on the improvements made
Hand over the improvements to the process owner

Control plans:

One or more approved documents
Provides status of a process
Provides measurements/standards that define the process
Includes monitoring procedures
Includes response planning

Characteristics of control plans

Characteristics to control
Process step
Process step and characteristics documentation
Standards
- Specs
- Predictability
- The measurement system and analysis standards (verified by gauge R&R)
- Capability
Methods
- Owner and collector
- Data collection method
- Sampling procedures
- Analysis
Response Plan
- Out of specification
- Out of control
- Unacceptable measurement system
- Incapable process
Improvement
Data to report to process owner
Format
When to report

Why use a Control Plan

Defines and describes the process
Aids in training and audit activities
Provides for timely process troubleshooting
Links process knowledge and response
Sustain process improvement

Plans link response to process information

One point falls beyond zone A
Two out of the three consecutive points fall in zone A or beyond
Four out of five successive points fall in zone B or beyond
Eight straight points fall on one side of the centerline

Once the improvements are implemented, the team must ensure that the project goals are attained and that the specified measures for sustainability are in-place. Lean principles, like mistake-proofing, encourage the team to style the method in a way that doesn’t permit errors to require a place, while SPC charting allows the method outputs and inputs to be monitored. The availability of process data, the value of collecting them, and the possibility of genuinely mistake-proofing a step are all critical considerations in determining what sort of control to use. Regardless of the tactic, the common theme among all Control phase tools remains the same: the functional owners of the improved process got to have bought into the new way of doing business. The buy-in is the ultimate Control plan, ensuring that the improvements will stay in situ long after the team has been disbanded.

Control Plans how they are done?

Administrative section
- Critical identification, approval, document control
Plan
- Information on the process
- Measurement used
- Control chart (if appropriate)
- Corrective actions to Out-of-Control conditions
Other
References to Standard Operation Procedures (SOP)
Emergency response plans
Links to Failure Mode and Effects Analysis