Control Plans

Johnson Controls, Inc. © January 2006 1 W4ControlPlans.ppt

 Control Plans
Contents
• What is a Control Plan?
• Control Plan Strategy
• What to Control?
• Identifying KPIVs
• Why Use a Control Plan?
• Developing a Control Plan
• Choosing the Right Level of Control
• Example of a Transactional Control Plan
• Components of a Control Plan
• Preventative Maintenance
• Example of a Manufacturing Control Plan
• Control Plan Worksheet

Johnson Controls, Inc. © January 2006 2 W4ControlPlans.ppt

 Learning Objectives
After completing this module, you will be able to…

1. Develop and implement control plans.

2. Identify the appropriate KPIVs to be measured.
3. Identify the appropriate measurement tool.
4. Transfer knowledge and responsibility for
process control to appropriate position(s).

Johnson Controls, Inc. © January 2006 3 W4ControlPlans.ppt

 Six Sigma Roadmap - Control Plan

Measure

Characterization

Analyze
Breakthrough
Strategy
Improve

Optimization
Used to ensure that
Control gains are achieved
and sustained.

Johnson Controls, Inc. © January 2006 4 W4ControlPlans.ppt

 What is a Control Plan?
• A written summary description of the system for
controlling a process
• Describes actions required to maintain the
“desired state” of the process and minimize
process and product variation
• A living document which evolves and changes
with the process and product requirements

Johnson Controls, Inc. © January 2006 5 W4ControlPlans.ppt

 Control Plan Strategy
A good control plan strategy…

• Minimizes process tampering.

• Clearly states the reaction plan to out-of-control conditions.
• Signals when Kaizen activities are needed.
• Describes training needs for standard operating procedures.
• Describes maintenance schedule requirements.

A good control plan clearly describes what actions

Important to take, when to take them, and who should take
them… thereby reducing “fire fighting” activities.

Johnson Controls, Inc. © January 2006 6 W4ControlPlans.ppt

 What to Control
Y = f ( x1, x2, x3…)

KPOV KPIVs

Monitor Control

A control plan controls the Xs to ensure the desired state for Y.

Merely monitoring the output, Y, is not an effective way to control
a process.

Johnson Controls, Inc. © January 2006 7 W4ControlPlans.ppt

 Identifying KPIVs
Sources for identifying KPIVs:
• FMEA
• C & E Matrix / Diagram and Cause Verification
• Regression Analysis
• DOE

Johnson Controls, Inc. © January 2006 8 W4ControlPlans.ppt

 Control Plan Tools
Developing and executing control plans requires
the use of…

• Control charts
• Error proofing
• Standard Operating Procedures
• Measurement System Analysis
• Preventative Maintenance

Johnson Controls, Inc. © January 2006 9 W4ControlPlans.ppt

 Why use a Control Plan?
• Provides a single point of reference for
understanding process characteristics,
specifications, and SOPs
• Enables orderly transfer of responsibility for
“sustaining the gain”

Johnson Controls, Inc. © January 2006 10 W4ControlPlans.ppt

 Developing a Control Plan
• Start with a basic understanding of the process
– Form a multi-function team
– Use tools & techniques to understand & document
• process flow diagram
• failure mode and effects analysis
• special characteristics (critical & significant)
• control plans / lessons learned from similar parts or processes
• team knowledge of the process
• technical documentation
• validation plan results
• optimization methods

Johnson Controls, Inc. © January 2006 11 W4ControlPlans.ppt

 Developing a Control Plan (continued)
• Questions to Get Started
– What do you want to control?
– How often do you need to measure the process?
– Do you have an effective measurement system?
– What is the cost of sampling?
• How much shift can you tolerate?
– Who needs to see the data?
– What type of tool/chart is necessary?
– Who will generate the data?
– Who will control the process?
• Have they been trained?
– What are the system requirements for auditing & maintenance?

Johnson Controls, Inc. © January 2006 12 W4ControlPlans.ppt

 Choosing the Right Level of Control

Instructions

Operational

Poka - Yoke
Instructions

Written
Verbal

Method

P DFSS
Sheets
(OMS)

SPC
Amount of Control

Amount of Effort Expended

Johnson Controls, Inc. © January 2006 13 W4ControlPlans.ppt

 Example of Transactional Control Plan

Transactional Control Plan

Prepared by: J. Dukarski Business Unit: Toyota Page 1 of 1: 1
Approved by: Location: Georgetown Document No:
Process Owner: Department: Prototype/Purch. Rev date: 18-Aug-00
Supercedes:

Process. CharacteristicCTQ/CLSpecificationMeasurement Sample Who Where Decision Rules Reference

Step Parameter RequirementMethod Size Frequency MeasuresRecorded Corrective Action Number
Customer Access All Access 1. Review reason for
Purchase order entry Database
entered Buyer Database length (eg. Weekend,
Order Time of Entry CTD to PO Less server All error) and determine
entered need for problem solve
than 3 days time stamp

Johnson Controls, Inc. © January 2006 14 W4ControlPlans.ppt

 Components of a Control Plan
• Administrative Data and linkages
• Substantive Data
– Who, what, where, and how

Johnson Controls, Inc. © January 2006 15 W4ControlPlans.ppt

 Administrative Data
• Identification
• Linkages
• Documentation identifiers
– System / Written information storage
– Plant, Engineering, Department reference(s)

Johnson Controls, Inc. © January 2006 16 W4ControlPlans.ppt

 Process Step
• Distinguishes process / process step / equipment
• Provides basis for standardization

Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 17 W4ControlPlans.ppt

 Characteristic/Parameter
• Identifies which KPIV or KPOV to measure
• Determined from project efforts / Team decision
• Consider standardization of similar process / equipment
• CTQ classification
– impacts performance
– proven results in defects or shrinkage if not measured &
controlled
Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 18 W4ControlPlans.ppt

 Specification/Requirement
• Determined from project efforts, technology /
process history
• Utilize variable data if possible
• Start with current specifications unless changed /
established by methodology
Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 19 W4ControlPlans.ppt

 Measurement Method
• Identifies tool / gauge / method used for measurement
• Consider availability of equipment
• Consider calibration and MSA needs
• Consider training on use of tool / gauge / method
• Supporting MPI, Operational Blueprint needed

Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 20 W4ControlPlans.ppt

 Sample Size - Frequency - Who
Measures
• Determine parameters to evaluate / maintain control
• As you assess the process over time, requirements might
need modification
• Who measures may vary by location / skills - reaction is
critical to success

Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 21 W4ControlPlans.ppt

 Where Recorded
• Control sheets recording - charts, plots, log, check sheets
• Control methods should be customized for floor / function
application
• Use as much quantitative information as possible
• Paper charting may be more suitable as a starting point
vs. system

Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Mesures Recorded Rules Number
Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 22 W4ControlPlans.ppt

 Decision Rule / Corrective Action
• Identifies reaction to out of control / specification situation
• References support documentation - OBP, trouble
shooting maps, etc.
• Facilitates access to documented correct procedures

Process Characteristi CTQ/CL Specification Measureme Sample Frequency Who Where Decision Reference
Step c/ Parameter Requirement nt Method Size Measure Recorded Rules Number
s Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 23 W4ControlPlans.ppt

 Reference Number
• Facilitates access to documented correct
procedures

Process Charateristic/ CTQ/CL Specification Mesurement Sample Frequency Who Where Decision Reference
Step Parameter Requirement Method Size Measure Recorded Rules Number
s Corrective
Action
Purchase Time of CTD Customer Access All All Buyer Access 1.Review
Order Entry Order entry Database entered entered Database Reason for
to PO less server time Length (eg.
than 3 days stamp Weekend,
error) and
determine
need for
problem
solve

Johnson Controls, Inc. © January 2006 24 W4ControlPlans.ppt

 Preventative Maintenance
• Inclusion of documented Preventive Maintenance
is an important element
• Ensure system established to do PM regularly -
need prompting method

Johnson Controls, Inc. © January 2006 25 W4ControlPlans.ppt

 Sample Manufacturing Control Plan
Part Name/Family: Prepared by: Page: of
Part Number: Approved by: Document No:
Plant/Area: Rev. Date:

Process / Characteristic Specifications/ Measurement Sample Who Where Decision Rule/

CTS Frequency
step/ / Parameter Requirement Methed Size Measures Recorded Corrective Action

If out of control
condition appears,
100% inspect all
Injection
parts since last
Molding Y : Part 3.250 + 0.005 in. X Bar & R
CTQ Gage # 042 5 Each hour Operator check. If X Bar out-of
(Machine Dimension Cpk=2 Chart
control, adjust
# 16)
injection pressure. If
R out-of –control,
adjust coolant flows.

If out-of-control
condition appears,
Pressure X Bar & R
X : Cavity 1200 + 15 psi (automatic, check: Injection
“ Pressure
CTQ
Cpk = 2
transducer in 5
continuous reading)
(automatic,
pressure settings;
cavity on monitor)
Temperature
controller.

If flow in yellow,
adjust to green. If
Check
X : Coolant Flow meter on flow in red, 100%
“ Flow
CTQ 5 gal / minute
machine
1 Each hour Operator Sheet by
inspect all parts since
Machine
last check, and adjust
flow to green.

Johnson Controls, Inc. © January 2006 26 W4ControlPlans.ppt

 Control Plan Worksheet
1. What is the Process Step?
2. What is Y, and what is its desired state (specification, requirement
for Y)?
3. What X do you want to control?
4. Does a measurement system for X already exist?
- Is it adequate / validated?
5. What is the specification / requirement for the X?
6. How much data needs to be collected?
- How often?
- By whom?
7. What control “device” should be used (control chart, ect.)?
8. What is the reaction plan?
9. Does the process owner understand the controls?

Johnson Controls, Inc. © January 2006 27 W4ControlPlans.ppt

 Exercise 2.1 : Control Plans

1. Refer to your workbook.

2. Break into small teams.

3. Follow the Control Plan worksheet to create a

control plan for your project.

Johnson Controls, Inc. © January 2006 28 W4ControlPlans.ppt