This material was produced under grant number SH-22316-SH-1 from the Occupational Safety - PowerPoint Presentation

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This material was produced under grant number SH-22316-SH-1 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

Control Plans

Presented

By The University of Texas-School of Public

Health

By the end of this module participants should be able to:Identify the concept of a control plan

Identify the importance of a control planDescribe the five

elements of a comprehensive Control PlanDefine project sign-off

Learning Objectives

Define

Measure

Analyze

Improve

Control

5

Phase

Tools

:

Controls Plans

Lean Visual Controls

Mistake Proofing (Poke Yoke)

The DMAIC Process with Tools

DAY 3

What is a Control Plan?

A control plan is:A written summary for monitoring or controlling processes or variation

A formal document that details all control methods used to meet goalsA

living document to be updated as new measurement systems and control methods are added for continuous improvementOften used to create concise operator inspection sheetsAn ESSENTIAL portion of final project reportA control plan is not:A replacement for instructional information contained in detailed operating, maintenance, or design manuals

Why is a Control Plan Necessary?

Sustainability Control plans require stakeholders to follow designated control methods to guarantee quality throughout system Prevents the need for constant heroes in an organization who repeatedly solve the same problems

Control plans are becoming more of a customer requirementTrack benefits

Reference for results not sustained

Who Should Create a Control Plan?

The team working on the projectANYONE who has a role in defining, executing or changing the process:Associates

Technical ExpertsSupervisorsManagers

Site ManagerHuman Resources

1. Aligning Systems &

Structures2. Documentation

Plan3. Monitoring Plan

4. Response Plan

5. Training Plan

Five Control Plan Elements

1

1. Aligning Systems &

Structures

2. Documentation

Plan3. Monitoring Plan4. Response Plan5. Training Plan

Five Control Plan Elements

Process owners accountable to maintain new level of process performance

.

The team develops the Control Plan by utilizing all available information from

the DMAIC phases.

1. Aligning Systems and Structures

Create a control plan that supports people to change their behaviors permanentlyPerformance goals/objectivesPolicies/procedures

Job descriptionsIncentive compensationIncentive programs, contests,

etc Evaluate measurements to ensure they align with desired behaviors Beware of multiple measures for the same desired behaviors

2. Documentation Plan

Documentation is necessary to ensure that what has been learned from the project is shared and institutionalized

Used for on-going trainingMust be updated prior to transition to customer (Final Report)

Items to be included in the documentation planRoles and responsibilitiesUpdated process maps/flowcharts Procedures (SOP’s)FMEATraining manualsMonitoring planResponse/ escalation planChange management process (updates, ownership)

Purpose Assures gains are achieved and sustained

Provides insight for future process improvement activitiesSustainabilityFunctional managers are responsible for adherence to the monitoring plan

Training and accountabilityStatistical process control

Control chartsPosted in area where data collected, plotted real-timeRecord actions taken to achieve in-control results.Alert ManagementSignals to trigger action (can be visual and/or audible)Red/yellow/green reports or pagers to signal process performance5S is necessary for Visual Management3. Monitoring Plan

4. Response Plan

Response plans—outline process(es

) to follow when there is a defect or Out of Control point from monitoring:Out of control point on control chartNon random behavior within control limits in control chart

Condition/variable proven to produce defects present in processMethod for keeping track of defects or “out of control” points over timeComponents of response plan:The triggers for a responseWhat are the failure modes to check for?Usually monitor the highest risk x's in the processDocument the recommended responses and responsibilities Communication strategy for updates

5. Training Plan

Who?Who requires training?

People who are involved in or support the process or are impacted by the improvementEmployees new to the process, department, etc. or needing a refresher

Who will provide the training (and create the training materials)?The planning, development and execution is a responsibility of the project teamWhat?What topics or modules need to be covered?Should different modules be available for different audiences?When?When will training be conducted?Consider busy seasons, different shifts, how long will the training takeHow? In what format will the training be delivered?Some options include online (CBT), workshop, on-the-job, etc.

Project Sign Off

Establishing a Control Plan is an essential element to successfully closing a projectBest method to assure acceptance of a Control Plan is having supervisors and management for the area involved.

During your report-out, remember to highlight specific changes to the process that are included in your Control PlanCommunicate where the Control Plan lives, and the Change Management Plan for making changes and communicating those changes to all involved parties

Exercise # 1:

In teams, select an element of one project and create a Training Plan to address the following questions:

Who?

Who requires training?Who will provide the training (and create the training materials)?What?What topics or modules need to be covered?Should different modules be available for different audiences?When?

When will training be conducted?

How?

In what format will the training be delivered?

SummaryA control plan is a written summary for monitoring or controlling processes or variation.

Five Control Plan Elements1. Aligning Systems & Structures2. Documentation Plan

3. Monitoring Plan4. Response Plan5. Training Plan

Best method to assure acceptance of a Control Plan is having supervisors and management for the area involved.

Thank You