DMA I C
Control Overview
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DMA I C
Control Phase
What is it?
The Control
The Control phase
phase implements
implements the the full-scale
full-scale
solution, ensures
solution, ensures that
that the
the solution
solution isis sustainable,
sustainable,
and shares
and shares lessons
lessons learned
learned inin the
the project
project
throughout the
throughout the organization.
organization.
Why do we do it?
In Control,
In Control, systems
systems areare put
put into
into place
place that
that will
will
prevent the
prevent the process
process from
from reverting
reverting toto its
its prior
prior
state. Also
state. Also during
during this
this phase
phase information
information isis
documented and
documented and shared
shared toto help
help accelerate
accelerate
similar projects
similar projects in
in other
other areas
areas ofof the
the company.
company.
2
DMA I C
Control Phase
What are the key elements?
There are
There are 66 key
key elements,
elements, or
or deliverables,
deliverables, in
in
the Control
the Control phase:
phase:
1.
1. Implementation Plan,
Implementation Plan,
2.
2. Operating Tolerances,
Operating Tolerances,
3.
3. Validated Measurement
Validated Measurement System,
System,
4.
4. Control Plan,
Control Plan,
5.
5. Updated Stakeholder
Updated Stakeholder Analysis,
Analysis,
6.
6. Project Closure
Project Closure
3
DMA I C
Control - Implementation Plan
Why do we need a plan?
AA good
good Implementation
Implementation Plan Plan organizes
organizes thethe tasks
tasks
and resources,
and resources, sets
sets time
time frames
frames and
and deadlines,
deadlines,
and identifies
and identifies actions
actions necessary
necessary to
to ensure
ensure the the
successful full
successful full scale
scale implementation
implementation of of the
the
improvement.
improvement.
What else is involved?
Other than
Other than resource
resource commitments
commitments andand timelines,
timelines,
the Implementation
the Implementation Plan
Plan addresses
addresses issues
issues like
like
change management,
change management, risk
risk management,
management, as as well
well
as describes
as describes budget
budget details
details and
and control
control
mechanisms.
mechanisms. 4
DMA I C
Control - Operating Tolerances
Upper
Spec
Y
Lower
Spec
Lower Upper
Set Set
point point
5
DMA I C
Control - Validated
Measurement System
Didn’t we do this already?
Back in
Back in the
the Measure
Measure phase,
phase, wewe did
did aa MSA
MSA
(Measurement System
(Measurement System Analysis)
Analysis) on
on the
the Project
Project YY
to be
to be sure
sure we we didn’t
didn’t call
call good
good data
data bad
bad or
or bad
bad
data good.
data good.
Now we
Now we must
must dodo MSAs
MSAs forfor the
the Xs
Xs to
to be
be sure
sure thatthat
the variation
the variation in
in the
the tolerance
tolerance limits
limits we
we set
set isis not
not
too great.
too great.
6
DMA I C
Control - Control Plan
What is a Control Plan?
As the
As the name
name implies,
implies, aa Control
Control Plan
Plan outlines
outlines the
the
strategy for
strategy for maintaining
maintaining the
the improved
improved process
process
performance over
performance over time
time by
by defining
defining specific
specific actions,
actions,
tools, and
tools, and responsibilities.
responsibilities.
AA good
good Control
Control Plan
Plan will
will incorporate
incorporate methods
methods such
such
as mistake
as mistake proofing,
proofing, robust
robust design,
design, monitoring,
monitoring,
drawings, process
drawings, process maps,
maps, and and procedures.
procedures. Other
Other
methods frequently
methods frequently used
used include
include checklists,
checklists, control
control
charts, and
charts, and response
response plans.
plans.
7
DMA I C
Control - Control Plan
8
DMA I C
De-Watering Steam Control Plan
Measurement Type of
Type Characteristic Capability Method MSA Control Frequency Signal Action Responsibility
Discuss at daily
Every other Week in Operations meeting. Proc Eng
KOPs
De-Watering OCAM Tag formal meeting. Insure Xs are on (formal)
Y 0 DPMO 26% Control > 1.75
Steam Ratio (New) Once a day on target. Process Eng Oper Supt
Chart
OCAM KOPs graph to check for (daily)
mechanical problems.
Operations Planning
will control model to
Glycol Whenever updated
Spreadsheet indicate best Operations
X1 Optimizing N/A N/A N/A pricing is available N/A
Model operating conditions Planning
Model (at least Monthly)
(Xs). Will discuss
results with Oper
Every other Week in Off Target Operations Supt to
KOPs Oper Supt
Reactor EO Not OCAM Tag Not formal meeting. (Target consult Unit
X2 Control and Planning
Concentration Tested (G6AI205C) Tested Once a day on from Oper Supervisor and
Chart (Target)
OCAM KOPs graph Pln) Cosole Operators
Every other Week in Off Target Operations Supt to
KOPs Oper Supt
Effect Reflux Not OCAM Tags Not formal meeting. (Target consult Unit
X3 Control and Planning
Rates Tested (G6FC201) Tested Once a day on from Oper Supervisor and
Chart (Target)
OCAM KOPs graph Pln) Cosole Operators
9
DMA I C
Control - Updated Stakeholder
Analysis
DM A I C
Define: Stakeholder Analysis
What is a Stakeholder?
AAStakeholder
Stakeholderisisany
anyperson
personor
orgroup
groupofofpeople
peoplewho
who
are:
are:
1.1. Likelyto
Likely tobe
beaffected,
affected,positively
positivelyor
or
negatively,
negatively, bythe
by theproject;
project;
2.2. Inaaposition
In positionto
toassist
assistor
orblock
blockthe
theproject;
project;
3.3. Expertsor
Experts orspecial
specialresources
resourcesthatthatcan
can
substantiallyaffect
substantially affectthe
thequality
qualityofof
theproduct;
the product;
4.4. Responsiblefor
Responsible forthe
thefinal
finaldecision.
decision.
10
DMA I C
Control – CAP/Stakeholder Analysis
The purpose of CAP in the Control Phase is it to “Make
Change Last” , which seeks to:
• Assure consistent, visible, and tangible
reinforcement that the change exists.
• Drive change to organizational systems and
structures to make the change part of individual and
team behavior.
• Recognize that change initiatives compete for time,
resources and attention.
• It initializes risk abatement and management of
these factors.
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DMA I C
Qx A = E
Quality of Six Sigma solution x its Acceptance = Effectiveness
Te
c hn
ica
lA
t ta
ck
/
at io n
g aniz k
/ Or Attac
am ral
e
T ultu
C Business
Results
12
DMA I C
Control - Project Closure
How do we know when to stop?
ItIt isis typically
typically time
time to
to end
end aa project
project when:
when:
-- the target
the target has
has been
been achieved,
achieved,
-- the new
the new process
process isis stable
stable and
and meets
meets the
the CTQs,
CTQs,
-- financial benefits
financial benefits are
are being
being realized,
realized,
-- metrics are
metrics are in
in place
place for
for ongoing
ongoing monitoring.
monitoring.
13
DMA I C
Control - Project Closure
START END
Lower Upper Lower Upper
Spec Spec Spec Spec
Limit Limit Limit Limit
DPMO = 450,000 DPMO = 9,500
Zst = 0.5 Zst = 3.9
Project Savings
140,000
120,000
100,000
80,000
$
60,000
40,000
20,000
0
M
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CL
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NT
NT
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DMA I C
Control Phase Summary
There are
There are 66 key
key elements,
elements, or
or deliverables,
deliverables, in
in
the Control
the Control phase:
phase:
1.
1. Implementation Plan,
Implementation Plan,
2.
2. Operating Tolerances,
Operating Tolerances,
3.
3. Validated Measurement
Validated Measurement System,
System,
4.
4. Control Plan,
Control Plan,
5.
5. Updated Stakeholder
Updated Stakeholder Analysis,
Analysis,
6.
6. Project Closure
Project Closure
15
DMA I C
Control Phase
Team Member Duty
Input from
Input from Team
Team Member
Member at
at Control
Control phase:
phase:
1.
1. Control Plan
Control Plan
--Team
Teammeeting
meetingto toagree
agreeononcontrol
controlplan
plan
--Meet
Meet Criteria
Criteriasuch
suchasasMistake
Mistakeproofing,
proofing,
Robust Design,
Robust Design, Monitoring
Monitoring&&
Respondplan
Respond plan
2.
2. ImplementationPlan
Implementation Plan
--Help
Helpininmonitoring
monitoringthe
thecontrol
controlplan
plan
--Ensure
Ensuretransition
transitionto
toprocess
processowner
owner
Reward Recognition
completed Reward
completed Recognition
Team Members
Team Members will
will received
received recognition
recognition for
for
every closed
every closed project
project
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