What is Control Plan in Six Sigma

The good thing about the Six Sigma methodology is that it follows a data-driven and logical approach to resolving issues. But, you might wonder what sets this methodology apart from other quality practices. Many factors make Six Sigma methodologies special. For instance, they are popular for their applicability and versatility. These things happen not only in manufacturing. But, well outside the purview of production, where the conception happens. Many effective tools are commonly used and belong to the Six Sigma Arsenal. One such tool is a control plan.

What is a Control Plan?

Before moving further, you should first learn what is control plan. It is nothing but a document that describes crucial quality characteristics and the most important components that are part of the process.

With a control plan, it will be possible to meet customer requirements. Once the customer requirements are rightly understood, it will be easier to bring down process and product variation.

You can use a control plan in a Six Sigma organization. Nevertheless, it should not act as a replacement for detailed operator instruction in the form of standard operating procedures or work instructions. In the production process, every process or part should have a control plan. Nevertheless, you can frame a single control plan for a group of common parts that share the process commonly.

In short, you can imagine a control plan as a living document. Its purpose is to outline the techniques for quality control of the most essential inputs. In turn, it will be possible to deliver outputs that customers expect. Even, the control plan offers a written description of checks, inspections and measurements that are put in place to control production processes and parts. Whenever a new process is implemented or there is a change in the existing process, the control plan functions as a PPAP. Also, it is maintained with consistency for showcasing real-time updates. Here, PPAP stands for Production Part Approval Process.

The Relationship of Control Plan With Process Control Diagram and PFMEA:

An organization should not overlook the fact that there is a direct relationship between the control plan from and to PFMEA and the process control diagram. Here, PFMEA denotes Process Failure Mode Effects Analysis. These two are the source of straight inputs to a control plan. These inputs encompass:

• Preventive measures taken to get rid of the risk of failures
• Potential causes of failure
• Potential effects of failure
• Potential failure modes

Six Sigma Control Plan – Meaning:

Now, you have a general idea of what a control Plan is all about. But, you are here to learn what is Control Plan in Six Sigma, isn’t it?

In Lean Six Sigma, a control plan is nothing but a detailed written description of the process. It helps readers understand the steps to take to keep the device or process running at its present performance level. From the document called control plan, it will be possible to get a detailed idea of every step and the parameters that should be watched to keep away from variations or deviations from the average performance of a group of products.

In Six Sigma Control Plan, you will find that it encompasses two elements. They are process monitoring and process control.

• Process monitoring is a tool that is otherwise called process summary. From this summary, you can gain visibility, review and action on all crucial process outputs within an organization.
• When it comes to process control, it relies on an instrument named process control plan. This plan generates feedback looks and takes actions to make sure that the process is under continuous control. With a good process control plan, you can  change throughput rates, information, materials and equipment without an effect on the process quality.

How Does Control Plan Work?

In any organization that uses the Six Sigma methodology, there will be a visual layout for a phase named the control plan phase. This outline encompasses different phases in manufacturing, a description of probable problems and pre-planned reactions to those issues if they come up. It describes the quality control measures to be taken in different circumstances.

Templates for control plans differ from one organization to another. However, once your organization identifies a suitable template, things will become easier thereafter.

Why Use A Control Plan?

You know what is control plan in Six Sigma. Nevertheless, you might wonder why have one in your Six Sigma organization. The important reason to have a control plan is to restrict variation. It helps with achieving the restriction by making quality control requirements easy to find and clear. In turn, your staff can test new items not only with ease but also quickly. So, bringing new people on board will be simple as well.

Things to Be Aware of Before Developing A Control Plan:

Now, you know what is control plan in Six Sigma and why you should use one.

Control plans in Lean Six Sigma are highly important for decision-making. The plans should be framed after careful evaluation of the status of the project from varied angles. These attributes must be taken into consideration before the start of the project. Here are a few attributes to consider:

Recording:

It is crucial to take note of the details at all stages of the project to enable assessment, implementation, testing and planning. Not only to record but also to storing of information about a process or product, plan sheets can be helpful.

Identification of Process Owner and Documentation:

Process owners are groups of individuals with the authority and responsibility to make any modifications to the process when the project progresses. To establish accountability for actions, it becomes important to identify process owners early in the process.

Corrective Measures:

When you take the case of any control plan in Six Sigma, it should encompass a framework for the implementation of corrective actions.​​​​​​​

Design of Process and Execution:

Also, it is imperative that the control plan should be developed around the central process. Its creation is for the identification of suitable standards and the setting of performance criteria.​​​​​​​

Reporting and Sampling Frequency:

It is better to have a specific schedule for reporting and sampling. With a set schedule, it will be possible to get sufficient time for correcting any errors. Even, with regular schedules, it will be possible to achieve tighter monitoring and control.​​​​​​​

Specifications and Measurements:

It is important to develop a control plan after carefully analyzing the expectations and perceptions of customers. In turn, it will be possible to make sure that the final product meets the specifications of customers.​​​​​​​

Input and Output:

It is crucial to identify the different IO parameters along with the stages at which they get into and get out of the control process. In turn, it will be possible to make sure of the free flow of control details. This is something important for the success of a project.​​​​​​​

Control Plan – An Industry Example:

The sales team in an organization recently completed a project. The project aimed at bringing down the number of voids of their crucial products on customer shelves. A shelf is considered void when the product is absent from the shelf. If a customer cannot find a product on the intended shelf, he/she will choose the product of a competitor.

To prevent customers from opting for the competitor product, a team worked on recommended improvements. The team then implemented the changes.​​​​​​​

What Should be Part of a Typical Control Plan?

Knowing what is control plan in Six Sigma alone is not enough. When you are engaged in developing a control plan, it is better to learn what forms part of a typical control plan:

The thing to remember here is that a control plan may encompass a few or many items based on the scope of the project or process under construction. Nevertheless, a typical control plan can include the following items:​​​​​​​

Process Step:

The process step should be one of the columns in a control plan created in the form of a table. It will have the label or name of the step in the process. For instance, if the business involves the usage of lathes in the backyard garage, it may select to include delivery, fine polishing, rough polishing and tool preparation as different steps involved in the whole process.​​​​​​​

Process Flowchart:

Most control plans encompass a visual representation of the process workflow along with different stages of decision-making highlighted. This provides a high-level and broad overview of the process for quick and easy reference at any stage.​​​​​​​

Specifications:

This item might be used for recording the numerical values of the specifications along with the unit of measurement.​​​​​​​

Frequency of Measurement:

This value is an indication of the frequency with which samples are selected for measurement like daily, hourly, etc. ​​​​​​​

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Conclusion:

Along with these elements, a typical Control Plan can encompass additional critical components such as corrective action protocols, sample size determinations, specification characteristics, and measurement methods. In the Six Sigma methodology, the Control Plan stands as a cornerstone for guaranteeing the success of projects and processes alike. By providing a structured framework for monitoring, evaluating, and managing quality parameters, Control Plans enable organizations to uphold standards, mitigate risks, and deliver consistent results. As industries increasingly prioritize efficiency and excellence, the integration of robust Control Plans becomes indispensable for driving continuous improvement and fostering a culture of quality assurance. Simpliaxis offers comprehensive Six Sigma training in Control Plans as part of its Six Sigma curriculum, empowering professionals to implement effective quality management strategies and achieve operational excellence.