Six Sigma Green Belt Control Phase

What are the bulk of items in the control phase gate review which formally close the active project?

- Control Plan -Response Plan -Financial Review -Closure Report This final review should also serve as part of the formal recognition of the team's efforts by senior management.

Standardized worksheet displays

- Cycle time of each action -Value and non value added -Distance travel to complet ee distance traveled' Can identify areas for improvement

What should you do to close a project?

- Document the gains -Set expectations for process to operate at improved level -Document the lessons learned -Finalize the project documentation -Celebrate the success and recognize the team members

Process stability Data is used for

- Understanding behaviors of a population -Predicting outcomes

Rules for visual work centers

-Based on the concepts of lean -Located at the gemba (workplace) if the workplace is outside, often located in the control room. -Focused on what is preventing the team from making plan -Frequently and diligently updated - just prior to the daily meeting in most cases -owned and maintained by the work team itself -Cell phones off -Start on time and end on time -Focus on the exceptions - The owner of each metric provide feedback on any metrics that are not meeting targets. Focus only on the exceptions -No issues without actions -1person speak at a time -brief and focused: 15 to 20 minutes to avoid losing focus on priorities. (most important ) NO PROBLEM SOLVING. If there's an issues, write it up and nominate someone to follow-up.

Standardization

-People, machines, materials and methods and measurements to a state of being persistent, consistent and repeatable.

Documentation

-Standard operating procedures -Templates Maintain certification or registration with international standards organization

Nelson Rules (8)

1) Beyond Limits 2)Zone A 3)Zone B 4)Zone C 5)Trending 6)Oscillating 7)Good Good 8)Too bad

What else should the team prepare other than the control plan and response plan in the control phase?

1) Closure report 2) Summary to summarize the project and codify the things that went well, and the things that could have gone better for future reference.

Control Phase activities include:

1) Establish ongoing process monitoring 2) Develop control plan 3) Develop response plan 4)Confirm attainment of project goals 5)Handover project 6)Close project 7)Celebrate with team

What are the 3 primary sections a control plan has?

1) Process Map 2) Key Process Variables 3) The reaction plan

Control Phase Tools:

1) Statistical Process Control 2)Control Plan 3)FMEA 4)Response Plan/reaction plan 5)Handover plan 6)Closeout report

What are the 5 types of control charts and what do they calculate?

1) X-bar R 2)X-bar S 3)P Chart 4)U Chart 5)ImR Each control chart calculates the mean, standard deviation, and control limits in a different way, which is why it is important to understand which control chart to use. Different control charts should be used, depending on the sampling technique and data type (continuous or discrete).

Continuous Data ( Data Type)

1) individual moving range -Sample size = 1 2) Sample Size <6 xR 3) Sample Size > or= 6 xS

Discrete Data( Data Type)

1)Counts of defects -C-Chart - Constant Sample Size -U-Chart - Variable Sample Size 2) Proportion defective -NP-Chart - Constant Sample Size -P-Chart - Variable Sample Size

What sample size would be used for defective unites 0.1%or fraction of .001

1,000

Standardized work 1 Work Element sheet 2 Audit Sheet 3

1- What to do 2- How to do 3-How to sustain

DIscrete Data

A count or finite number of possibilities efers to information that can only take specific, distinct values and is countable in a finite amount of time. This type of data is typically categorical and often represented by whole numbers. Here are some key characteristics and examples of discrete data: Distinct Values: Discrete data can only take on distinct, separate values. There are no intermediate values between two adjacent data points. Countable: Discrete data can be counted in a finite manner. You can count the number of occurrences or items associated with each value. Categorical Nature: Discrete data often represents categories or groups. Each data point falls into one of these categories. No Fractional Values: Unlike continuous data, which can take any value within a range, discrete data cannot have fractional values. It is usually expressed as whole numbers.

Process Map

A map of the process is included in your control plan. This can be a simple flowchart or a swim lane chart. It is a good idea to show numbers on the map where your measurements take place in the process. Different symbols and colors should be used to designate the input (X), process (X), and output (Y) variables within the process map

Which control chart would you use to measure the number of truck failing their daily safety inspection each day (note sample size varies)? P-chart np-chart Either p- or np-chart U-chart C-chart Either u- or c-chart

A. The np requires constant sample size. U and C charts measure the number of defects per unit space or time.

Processes that are stable and capable should not be adjusted if they are in control. Why not?

Because adjusting a stable process will make it become unstable, and an unstable process will in all likelihood produce parts out of specification.

Why Processes that are stable and capable should not be adjusted if they are in control.

Because adjusting a stable process will make it become unstable, and an unstable process will in all likelihood produce parts out of specification.

When should you use a xS chart?

Continuous data that has a sample size greater than 10 example - inspecting software code (20 lines) uses the standard deviation to represent the spread in the data instead of the range, and is better when subgroup sample size is greater than about 8. The use of the standard deviation minimizes the impact of a single outlier in the range. Each individual data point on the averages chart consists of the average of the values within the subgroup. The s-bar centerline is the average of all of the standard devations in the sample set

When should you use a xR chart?

Continuous data when the sample size is less than 10 Sample sizes greater than 10 are typically not practical the averages center line is calculated by getting the average of the each subgroup average in the data set are given by constants as shown in the video. The range is defined as the difference between data point values in a subgroup. For example, if the first data point is 9 and the second data point is 14, the plotted value on the x-bar R would be 5. The R-bar centerline is the average of the ranges of all of the subgroups.

Control plan/Response Plan ( 1st Phase Gate)

Control Plan- Team will monitor the process to ensure the process stays at the desired state. Response Plans- Defines what the team should do if the process slips back into its old ways Be sure to document the appropriate actions in the control plan for monitoring the process, including how to react if it goes out of control. Similar to run charts as they use plotting overtime.

Include the following items in the project closure report:

Control plan Project charter Key project deliverables Signed project transition Contact information for all project participants Key supporting documentation by phase

When should you use a U Chart?

Defects per unit ( varying sample sizes) The number of injuries per patient in an ER ( discrete counting the number of people and injuries)

Check sheet

Designed to visually demonstrate a single task

To create a control plan

Determine the scope and boundary of a process to be controlled by using the future state process map Identify and list the most critical customer requirements (CCR) List the output results necessary to meet CCRs Identify and select the control points that best predict output results and define operational definitions for each process measurement Define the specifications and targets for each control point Describe the method for checking each control point on a regular basis Identify and describe the reaction plan if a control point does not meet specification limits or targets, or if issues surface that require actions Continue to identify new standards of process improvement and implement them

Project Documentation and Closure

Documenting the project allows you to keep a record for legal purposes, allows future Process Owners the opportunity to understand what happened, and facilitates the potential standardization of solutions to other processes within the organization. The final project closure documentation, often found in the form of a Closure Report, should also indicate the improved state of the process.

Nelson Rule 4 - Zone C description

Eight consecutive points fall on one side of the centerline

Nelson Rule 8 - Too Bad

Eight consecutive points miss Zone C (+/- 1 sigma)

The major focus of the Control Phase

Establish the controls needed to sustain the gains we've been able to generate through the first four phases.

the x-bar R chart is required if the sample size is less than 10. Reveal answers.

False. It is common to use the x-bar R when n < 10 because the range is easier to calculate, but it is not required, nor even desired if the calculations are automated.

Nelson Rule 7 - Too Good

Fifteen consecutive points fall within +/- 1 sigma May mean that the measurement system is broken

Nelson Rule 3 - Zone B description

Four out of five fall outside 1 sigma on one side of the centerline

Nelson Rule 6 - Oscillating description

Fourteen or more consecutive points alternate

Important concepts of standardized work include :

Heavy use of pictures and visual indicators Keeping all the information to a single page

When should independent financial review and validations of the savings occur?

If the project included financial benefits in the charter.

The benefits of applying solution standardization include:

Improved organizational strategies. This is based on better knowledge of actual process performance and capability Improved execution of strategy-driven action plans. This is due to projects being selected based on actual performance and not leadership assumptions Improved fact-driven knowledge transfer throughout the organization Improved deployment of resources to areas with real opportunities for improvement Improved performance of processes. This is due to regular attention from organizational leaders

What defines a stable process?

Inputs that do not change over time because that process is predictable

Statistical Process Control (SPC)

Invented to help companies be more proactive than reactive.

Daily huddles are normally kept to 10 to 15 minutes because:

It helps to maintain focus on what's important that day. Huddles should not be based on attention span. While huddles do impact efficiency, that is not a primary reason. Problem solving is not done during the daily meeting.

Inputs include

Man, Machine, Material, Methods, Measurements, & Mother Nature

Np Chart (actual number)

Measures the actual number of noncomforming units & normally used with a constant sample size The np requires constant sample size.

What does in control mean?

Normal variation (every process has normal variation)

Discrete Data Example

Number of Employees in a Company: You can't have a fraction of an employee, so the count of employees is discrete. Number of Cars in a Parking Lot: The count of cars is a whole number and is finite. Number of Students in a Class: Similar to the examples above, the number of students is a countable, finite quantity. Number of Defective Items in a Batch: The count of defective items is discrete because it involves whole numbers. Number of Books on a Shelf: The count of books is a discrete value.

Nelson Rule 1-Beyond Limits description

One point falls outside 3 sigma

Which control chart would you use to measure the number of truck failing their daily safety inspection each day (note sample size varies)?

P-chart

When should you use a P Chart used?

Pass/Fail process data Y axis - percentage of probability which is why they are called P charts Example - number of incomplete applications of of 100 used for counting defective units with a variable sample size. The p-chart monitors the proportion (percentage) of nonconforming units in a process. Each part produced must be inspected and declared good or bad; the proportion of nonconforming units in each subgroup serves as the plotted point in the chart. Use this chart when inspecting for nonconforming units and the subgroup sizes are not constant.

Project standardization

Project standardization is about implementing solutions that have been tested and proven to be best or significantly better practices at the original site.

P Chart stands for (percentage)

Proportion chart 9 (measures the fraction or proportion nonconforming)

What does out of control:

Special cause variation - caused by likely some change in the process

Types of Standards

Standard solutions Standardized work instructions Inspection and quality standards Process standards Customer standards Government and industry standards The last two items on the list are pretty much absolute standards, in that they are set by outside agencies (or the customer) and must be adhered to. Inspection, quality, and process standards normally flow from the external standards and generally must be met to ensure meeting them. That leaves the first two as potential candidates for discretionary standardization.

Continuous Data

Take any value within a given range and can be measured with a high level of precision. This type of data is often associated with quantitative measurements and is not limited to specific, distinct values. Here are some key characteristics and examples of continuous data: Infinite Values: Continuous data can take an infinite number of values within a given range. There are no gaps or interruptions between possible values. Measurable: Continuous data can be measured with a high level of precision. It is associated with real numbers and can include fractional or decimal values. Interval Scale: Continuous data is often measured on an interval scale, where the differences between values are meaningful. Temperature, for example, is measured on an interval scale. Graphical Representation: Histograms and probability density functions are common ways to visually represent the distribution of continuous data.

Continuous data example

Temperature: Temperature can take on any value within a range and is often measured with decimal precision. Height of Individuals: The height of a person can be measured with a high level of precision, including fractional values. Weight of Objects: Weight is continuous because it can take any value within a given range. Distance Traveled: The distance traveled by a vehicle or a person can be measured continuously. Time Elapsed: Time, when measured with precision, is considered continuous.

Control chart decision tree

The ability to choose the best control chart. It identifies how to select the appropriate chart based on the data.

The art of Standardization

The art is knowing what to standardize, when, and then, finally, how. The how is the easier part. The what and when are more challenging

How can the operator tell what's normal and what's not?

The control chart. Identify the process parameter that is most essential for product or service quality, monitor it using a control chart, and train the operators in how to interpret it. Sometimes the greatest value in the control chart is in its communication of when to leave the process alone!

Key process variables

The control points are listed. These are process metrics that have been determined to have a strong cause and effect relationship with the outcome indicators. Each control point has an operational definition with key target parameters that identify the performance required or desired for each control point and process. Each control point summarizes when checks will be performed, methods applied, and who is responsible to conduct these process checks

Proportion defective

The entire unit is either good or bad. A proportion can be calculate; binomial assumptions apply.

Without a proper understanding of control charts, you can make two types of mistakes that increase process variation.

The most typical mistake is treating common cause variation as though it is caused by special causes. Another common mistake is treating special cause variation as though it is due to common causes.

What does the c chart measure

The number of nonconformities in an inspection unit such as a plate of glass. measure the number of defects per unit space or time.

Applying a process control system results in what benefits?

The process is documented Standardization and replication happen Process priorities and performance standards are communicated Measures used to evaluate process performance are defined Data collection requirements and approaches are described Process performance and improvement efforts against targets are tracked Process reporting and improvements are made

Who receives the control plan and its corresponding response plan?

The process owner, often in a handover plan or package, to maintain the gains of the process improvement effort.

What takes place during the control phase?

The project team established process monitoring and creates a control plan that summarizes the controls you will use to ensure the process continues to operate at the level of performance we achieved coming out of the Improve phase.

Reaction Plan

The reaction plan defines which actions for each control point are to be taken if issues occur

when the sample size changes, what else changes?

The upper and lower limits

Count of defects:

There is no limit to the number of defects that can be counted. It is not possible to count the non defects

A process that is not well documented, is difficult to perform or has new people doing it every day is probably not stable True or False

True

An automated process that is well controlled and run by well-trained people is probably a stable process and a good place to use control charts. True or False

True

True or false The control plan needs to be viewed as a living document

True

ccessful implementation greatly depends on local management, especially the Project Champion and Process Owners.

True

true or false Standardization is one way that we maintain process stability

True

Before closing a project, the Process Owner must take ownership of the control plan to ensure an understanding and a commitment is in place to sustain the improvements.

True To properly transition the project to the Process Owner, the team should hold a final meeting to review and resolve all open issues, capture key process findings, and prepare a final report. At the end of the meeting, the Process Owner should formally take over the control plan.

True or False: Each sample should have, on average, at least one defective to allow the P and np control chart to be effective.

True. Average sample sizes of less than 1 would provide too tight of a control limit and many false positives to be used

True or False: Zone control rules generally should not be used on ImR charts.

True. Since the moving range calculation is not based on independent samples, the zone control rules should not be used

Nelson Rule 2- Zone A description

Two of the three fall beyond 2 sigma on one side of the centerline

Common methods used to indicate when a stocked item should be re-ordered include

Use of a kanban card on or in each container of parts Use of a line or physical marking indicating when a part should be reordered Use of a two-bin system, where re-ordering occurs immediately upon the first bin being emptied

When is a process stable?

When conditions and/or inputs are not changing

When are process improvements complete?

When the new and improved process is under control.

1. Which of the following is true about control charts? a. Control charts should only be used to analyze stable processes or to establish baseline capability such as use in a process capability study. b. There are many types of control charts, but they all calculate mean, standard deviation, and control limits the same way. c. If you know the number of samples you have, you know which type of control chart to use. d. A control chart is the best tool to use when the process is not documented or has new people using it every day.

a. Control charts should only be used to analyze stable processes or to establish baseline capability such as use in a process capability study.

1. The Food Services Manager at County General Hospital company is responsible for monitoring its shipments of food to ensure that each shipment has the same weight. The cafeteria receives one shipment of potatoes daily. The Manager records the actual weight in pounds. Which control chart is most appropriate to use? a. X-bar R Chart b. ImR Chart c. X-bar S Chart d. P Chart

b. ImR Chart

What is the greatest benefit of a control chart?

beyond identifying out of control conditions, they also indicate when process variation is only due to random variation.

Process dashboards

developed to drive compliance and provide visual management to the new process. They provide graphical data and information to make decisions and drive actions.

Visual controls

extend the concept of standardized and visual work instructions to the rest of the workplace

When should you use a IMR Chart(individual moving range chart)?

individual sample/ moving range Used when sample size equals to 1 (Continuous data) A subgroup is selected to calculate the range. a subgroup of 3 will be the third sample minus the first sample allows you to monitor and detect changes when there are no rational subgroups greater than size = 1. As with x-bar charts, ImR charts verify that the process variation is in control before evaluating the process average. You should use an ImR chart when measurements are expensive or not necessarily related, for products requiring a long cycle time for production, when each sample represents an entire batch, and when output is continuous and uniform. Example- inspecting the density of a diamond

What you should do after implementing the improvement solution?

it is important to validate the measurement system and determine the new process capability.

What does the center line mean on a control chart?

represents the average or mean of the process being monitored. In statistical terms, it is often denoted by the symbol "X̄" (pronounced as "X-bar"). The center line serves as a reference point for assessing the stability and performance of the process over time.

0.1 probability of finding atleast 1

sample size of 300

General sample size rule

sample size should be large enough to pertain 1 defect per sample

process control system

set of tools which define the management of the process and the factors critical to its success.A main component of the system is a control plan that provides a central summary of the key process variables which need to be effectively managed to ensure high levels of process performance.

Nelson Rule 5 - Trending description

six or more increasing (or decreasing) points in a row

Standardization of solutions requires

the integration of process leaders, managers, and process participants

One of the challenges with standardization

the process owners at other locations may not even realize that there is a problem with the process. A natural challenge when a successful solution has been approved for standardization is to balance the needs of the team members with the needs to maintain continuity throughout the implementation. It may be helpful to ask these two questions: What things should the team consider when planning to replicate a solution? What risks come with trying to replicate a solution?

What are control charts used for?

to understand stability and should only be used to analyze a stable process, which means that the same people are working on the process, they are using the same equipment, and they are following the same procedures.This is because a stable process is predictable.

standardized work instructions

tools that adhere to the principles of lean. They are highly visual, they are highly focused, they are summarized on a single page, and they are located at the Gemba where work is performed.

One of the most fundamental axioms in business improvement

you cannot improve an unstable process.

What should you do If the process isn't stable because a new piece of equipment is being installed or a new software application is being used

you must draw a hard line in your analysis and separate data collected from the previous state from data collected from the new state. Do not mix the new data with the old data because you will not return meaningful results.