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
![](https://leanmanufacturing.online/wp-content/uploads/2020/12/control-chart-1024x275.jpg)
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.
Links to Measurement System
- Is the measurement system stable and predictable?
- Are parts or items different?
- Are operators different?
- Are operators consistent?
- What is the measurement resolution?
- What is the measurement uncertainty?
- What is measurement discrimination?
- Are the measurement units adequate?
- Are the measurements stable over time?
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
![](https://leanmanufacturing.online/wp-content/uploads/2020/12/Control-plan-template-1024x492.jpg)
Summary – Control Plans
- Provides point of reference
- Links monitoring inputs and response
- Enables project completion
- Sustains long-term capability