CONTROL

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Control Phase
Goal: To sustain the gains from the improvements through
standardization, documentation and/or control

Output Deliverables:
✓ Control plan and/or monitoring system to facilitate sustenance of
gains
✓ Completed documentation, communication of results and lessons
learned and way forward

Complete Make
Design and Summarize and
documentation recommendation
implement communicate
and s for continuous
control methods lessons learned
standardization improvement

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 PROCESS
CONTROL PLAN

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What is a Process Control Plan?

▪ Process control systems include detailed measurement

instruction for monitoring the process.

▪ It helps to define the process measure target to ensure successful

and continuously improving performance.

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Process Control Plan Sample

Input or
Specs Limits / Person
No. What's Controlled? Output Control Method Frequency
Requirements Responsible
?

Control chart – X
1 Attendance Rate Output ≥ 95% Daily F. Veroya
bar & R

2 Attendance Checking Input Implemented Random audit Weekly F. Veroya

2 days before Records Daily,

3 Leave Filing Input J. Palisoc
actual leave checking Weekly

Control Method Examples ▪ Records Checking

▪ Audit ▪ Checklist
▪ Automation ▪ Fixture / Jigs
▪ Visual Inspection ▪ Training & certification
▪ Control Chart ▪ Gauges

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CONTROL
CHARTS

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What is a Control Chart?
▪ A statistical control chart is a line graph of the measurements of a
product or process over time that has statistically based control limits
placed on it.

▪ The points that are plotted on a control chart may be the actual
measurements of a part characteristic or summary statistics from
samples (subgroups) of parts taken as they are produced over time.

▪ A control chart has control limits based upon process variation and a
centerline representing the average of all the measurements used to
construct the control chart.

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Why Use a Control Chart?
▪ To display and manage variation in process output over time.

▪ To identify when a process changes.

▪ To provide a basis for improvement.

▪ To identify the causes of variation and process capability.

▪ To distinguish special from common causes of variation (that is, when to

correct sporadic problems or when to change the process).

▪ To help assign causes of variation.

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Control Chart Elements
Special Cause
Variation Run Chart of
Process is “Out data points
of Control”

Upper Control
Limit

+/- 3 sigma
Common Cause
Variation
Process is “In
Control”

Lower Control
Limit

Mean
Special Cause
Variation
Process is “Out
of Control”
Process Sequence/Time Scale

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 TEST FOR
SPECIAL CAUSES

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 Tests for Special Causes of Variation

Test 1 One point beyond zone A Test 2 Nine points in a row on Test 3 Six points in a row, all Test 4 Fourteen points in a
1
same side of center line increasing or decreasing row, alternating up and down

A A A 3 A

B B B B

C C C C

C C C C 4

B B 2 B B

A A A A

Test 5 Two out of three points in Test 6 Four out of five points in Test 8 Eight points in a row
a row in zone A (one side of center zone B or beyond (one side of Test 7 Fifteen points in a row in beyond zone C (both sides of
line) center line) zone C (both sides of center line) center line)
5 6
A A A A
B B B B
C C C C
C C C 7 C
B B 6
B B 8

A 5 A A A

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 SELECTING A
CONTROL CHART

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Control Chart Selection Guide

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Control Chart Selection Guide

Continuous Sample Size is Chart

1 IX - MR
≤8 X Bar and R
>8 X Bar and S

Attribute
Sample Size is
You are
counting Fixed Variable

Defective NP P

Defect C U

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CONTROL PHASE
WORKSHOP

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Control Phase Workshop

Based from the case study, the following should be provided:

1. From the list of implemented solutions, prepare and complete a

process control plan with all column details.

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