1. Lean Six Sigma DMAIC Workshop Green Belt Part 6
4/20/2017
Green Belt Training

2. Control
Control
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Green Belt Training

3. Develop Control strategy
Control Process Flow
Develop Control strategy
Develop control plan
Update SOP’s and training plans
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Green Belt Training

4. Prevention vs detection Visual Factory Control Plan Reaction Plan
Key Concepts
Prevention vs detection
Visual Factory
Control Plan
Reaction Plan
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Green Belt Training

5. Sustaining the gains is key!
Control Phase
Control is a means of sustaining improvements by eliminating the opportunity for defects to occur, or monitoring the process using a feedback system
Sustaining the gains is key!
We move from detection of defects to prevention of defects
4/20/2017
Green Belt Training

6. The avoidance of an error before it occurs
Error Proofing
The avoidance of an error before it occurs
Error-proofed processes are designed to require extensive operator training while allowing the operation to be performed the correct way EVERY time.
Automation
Fixtures
Jigs
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Green Belt Training

7. Visual Factory
Visual Displays
Communicate important information, but do not what people or machines do
Visual Controls
Communicate information and/or build controls into the process so that activities are performed according to standards
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Green Belt Training

8. Control Charts
Control Charts
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Green Belt Training

9. Variation exists in all processes
Variation means that a process does not produce exactly the same result every time the product or service is delivered
Variation exists in all processes
Measuring and understanding variation in our business processes helps identify specifically what the current level of performance is and what needs to change in order to reduce the variability and therefore reduce the defects delivered to customers
4/20/2017
Green Belt Training

10. Market What Causes Variation? Suppliers Process Inputs
Critical Customer Requirement
Market
Suppliers
Process Inputs
Business Processes
Process Outputs
Defects
Root cause analysis of variation leads to permanent defect reduction
Variation in the output of processes causes defects
4/20/2017
Green Belt Training

11. Help us to detect, diagnose, and correct
Control Charts - Basics
Control Charts
Have the ability to indicate the presence of special causes that upset our processes
Help us to detect, diagnose, and correct
production problems in a timely fashion
Provide an easy to understand visual
indicator of process performance
4/20/2017
Green Belt Training

12. Steps to building an appropriate control chart
Control Charts - Basics
Steps to building an appropriate control chart
1. Determine the type of data
2. Collect data consistently
3. Select the appropriate control chart
4. Build the control chart
5. Analyze process performance
6. Take corrective action
4/20/2017
Green Belt Training

13. Variation within a stable pattern is inevitable
Common Cause Variation
There are always inherent chance causes responsible for natural variation in all processes due to “normal” variation in materials, environments, methods, etc. (common cause)
Variation within a stable pattern is inevitable
4/20/2017
Green Belt Training

14. Special Cause Variation
Once we have an indication of a shift outside a stable pattern of variation, we must discover the reason for the shift (special cause)
We want to remove the influence of a special cause if it is adversely affecting product-process quality
If the special cause influence is improving product-process quality (e.g., 6 Sigma projects), we want to permanently capture its effect
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Green Belt Training

15. Out of Control Variation
Eliminate Special Causes
Commuting Time (mins)
In Control Variation
Out of Control Variation
Commuting Time (mins)
Days
Time
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Green Belt Training

16. It is critical to understand that:
Issues on Control Charts
It is critical to understand that:
Control charts do not tell us whether or not we
are meeting tolerance specifications
consistently
They neither explicitly identify nor remove
special causes
Control charts are statistical based devices for
addressing process stability
We need to develop meaningful process logs to account for and document physical characteristics, action items, and results obtained
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Green Belt Training

17. Charting Variation – Control Charts
Commuting Time (mins)
Days
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Green Belt Training

18. Improves overall quality by reducing chances of deviation
Benefits of a Well-Defined Control Plan
Improves overall quality by reducing chances of deviation
Reduces defects by keeping processes centered
Aid in timely troubleshooting of the process
Serve as a communication tool for changes in CCR‘s
Sustain improvements
4/20/2017
Green Belt Training

19. Characteristic/Parameter CCR Specification/Requirement
Control Plan Contents
Characteristic/Parameter
CCR
Specification/Requirement
Measurement Method
Sample Size
Frequency
Who measures
Where recorded
Decision Rule/Corrective Action
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Green Belt Training

20. Actions to be taken when an out of control condition occurs
Reaction Plan
Actions to be taken when an out of control condition occurs
When do we react?
Who needs to be involved?
What other information do we need to have?
4/20/2017
Green Belt Training

21. Procedures and Standards
Procedures and standards are the details behind the activities documented on the business process map
They serve as a vehicle for every employee -from senior executives to hourly workers -to gain an understanding of the improvement
Procedures are both a training aid and a means to ensure successful implementation
4/20/2017
Green Belt Training

22. They should describe how to prevent product and service variation
Procedures and Standards
Contents
They should be at such a level that the job can be performed well by employees who are not fully trained
They should be specific. Tell precisely what actions to take and when and where to take them. Make it clear where people‘s responsibilities lie
They should describe how to prevent product and service variation
They must be able to be followed. No contradictory or unrealistic instructions.
Priorities must be considered. Focus on the root causes
Formats
– Procedures – Checklists
– Flowcharts – Metrics
4/20/2017
Green Belt Training

23. Channels: There are numerous communication channels such as:
Communication Planning
Research has shown that one of the most significant variables in successful implementation is the quality of communications supporting a change. Teams must be very careful to develop the right communications for the right people and deliver them at the right time
Channels: There are numerous communication channels
such as:
One-on-one meetings
Electronic mail
Posters
Bulletin boards
Small discussion groups or workshops
Videos
Teleconferencing or video teleconferencing
Memorandums or personalized letters
Voice mail
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Green Belt Training

24. Do your research and preparation: Understand audience
Presentation Checklist
Do your research and preparation:
Understand audience
Include stakeholders
Anticipate questions
Presentation Opening:
Set the expectations
Share the burning platform
Establish a sense of urgency
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Green Belt Training

25. Present “As Is” and “To Be” Use facts and data
Presentation Checklist
Deliver Body:
Present “As Is” and “To Be”
Use facts and data
Show how stages of DMAIC tools were used
Sell Your Solution:
Be Specific
Provide Examples to prove point
Link Benefit/results to actions
4/20/2017
Green Belt Training

26. Present resource requirements Ask for approval Follow-up:
Presentation Checklist
Closing:
Make recommendations
Include How-By
Present resource requirements
Ask for approval
Follow-up:
Post presentation debrief
Publish meeting minutes
Thank participants
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Green Belt Training

27. Appendix
Appendix
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Green Belt Training

28. How to Apply this Tool in my Work
Statistical Tools Summary
Tool
What
Type of Data
When to Use
How to Apply this Tool in my Work
Histogram
Visual display of one variable
showing data center, spread,
shape and outliers
Continuous or
discrete
1. Summarize large amounts of data
2. To get a “feel for the data‟
3. To compare actual description to
customer specs
Multivari
Charts
Bar chart comparison of subgroups
on one variable.
To visually compare sub-groups by
individual data points and the mean.
In MINITAB 12 only. To identify
major source of variation.
Box Plots
Visual display of the
summary of Y data grouped
by category of X
Y=continuous
X=discrete or
categorical
Summary display to visualize
differences in data center, spread and
shape across categories.
Run Charts
Plots observation in time
sequence
Y=continuous or
To view process performance over
time for trends, shifts or cycles.
Control Charts
Plots observations in time
sequence against a mean and
control limits
To monitor the process in order to
control and improve process
performance over time for trends,
shifts or cycles. To identify special
causes.
Scatter
Diagram (Plot)
Plots a response Y versus a
predictor X
X=continuous
To understand the possible
relationships between two variables.
To identify possible root causes
which are related to Y. Do not use
with special causes.
4/20/2017
Green Belt Training

29. How to Apply this Tool in my Work
Statistical Tools Summary
Tool
What
Type of Data
When to Use
How to Apply this Tool in my Work
Behaviorally Anchored Scales
A response scale on which specific points are named or described to clarify the differences between points.
Discrete / Categorical: Nominal(name)
Ordinal(order)
Continuous: Interval
To translate subjective or qualitative issues into data (discrete or continuous). To reduce variation in the response measured.
t-Test
Determine if there is a difference between two groups.
Y=continuous X=discrete or categorical
Test if sample average = specified value
Test if 2 sample means are equal
Paired t: to reduce variation when comparing two sample averages Analysis
Analysis of Variance
Determine if there is a difference among many groups.
(2 or more Xs)
Determine of there is a statistically significant difference among the groups.
Discrete Data: Chi Square Determine
Determine if there is a difference for observed frequencies of 2 discrete variables.
Y=discrete or categorical
X=discrete or categorical
Determine if there are relationships between two discrete variables.
4/20/2017
Green Belt Training

30. How to Apply this Tool in my Work
Statistical Tools Summary
Tool
What
Type of Data
When to Use
How to Apply this Tool in my Work
Regression(Linear &Multiple)
Summarizes, describes, predicts and quantifies relationships.
Y=continuous X=continuous or discrete
Determine if there is evidence of a relationship between Xs and Ys.
Model data to develop a mathematical equation to quantify the relationship.
Identify root causes.
Make predictions using the model.
Logistic Regression
Y=discrete X=continuous or discrete
Design of Experiments(DOE)
Systematic and efficient proactive approach to testing relationships.
Y=continuous or discrete X=continuous or discrete
To establish cause and effect relationship between Ys and Xs. To identify “vital few” Xs.
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Green Belt Training

31. Websites: www.isixsigma.com www.asq.org/sixsigma/ www.minitab.com/
Control
Websites:
4/20/2017
Green Belt Training