Two tools used in the Control phase of the DMAIC cycle are the Control Chart, often called Statistical Process Control (SPC) Chart, and the Process Audit. You will use both tools t
Two tools used in the Control phase of the DMAIC cycle are the Control Chart, often called Statistical Process Control (SPC) Chart, and the Process Audit. You will use both tools to complete this assignment.
The Control Chart shows how a variable changes over time. Data are plotted in time order. A Control Chart always has a central line for the average. The chart also shows an upper line for the upper control limit (UCL) and a lower line for the lower control limit (LCL). This data helps to control processes, to predict outcomes, and to monitor the process. You will analyze a Control Chart provided in the assignment template.
You are analyzing the Control Chart as part of a Process Audit. You will be looking for “out of control” conditions and where the process is not working. You want to make sure the process is stable and meets requirements, so you will do some problem solving to figure out where and how to make changes in the process.
Before you begin, be sure to review the following resources:
- Process Audit (and Control Chart): https://www.youtube.com/watch?v=uPTdz8mkxi8
Download the Process Audit template here. (WILL ATTACTH FILE)
Use one of the opportunities for improvement (OFIs) that you discovered during your Benchmarking Report assignment or Eight Wastes assignment as a project. You are working on the Control phase of this project, trying to make sure that the process improvements you made during the Improve phase are working and stay working. Use the template provided to perform a Process Audit, including analysis of the Control Chart and solving problems with out-of-control conditions. Follow the question prompts in the template to work through the problem and bring the process back under control. Fill out the yellow areas to complete the assignment.
THE ORGANIZATION IS MY HOME AND THE OPPORTUNITY FOR IMPROVEMENT IS TO IMPROVE THE OVERPRODUCTION ON GROCERIES IN MY HOME.
Your Process Audit report must include:
- Organization Name
- Process Title
- Variable Being Tracked
- Out-of-Control Conditions
- Five-Why Root Cause Analysis
- Containment Actions (to "rope off" or secure the situation)
- Corrections (to get the situation back under control)
- Corrective Actions (to prevent recurrence of out-of-control conditions)
Process Audit
Organization Name
Process Title
Student Name
Variable You Are Tracking in Your Process
Assume the process control chart shown above represents a new process you and your team developed as part of an improvement project. You must audit or monitor the new process, using the control chart to make observations about how well the process is staying in control. You will determine which "time" attributes are out of control (above the upper control limit and below the lower control limit). I.e., which dots are out of control? For these fictitious out-of-control conditions, follow the question prompts below to work through the problem and bring the process back under control. Fill out the yellow areas to complete the assignment.
What is the variable that you are tracking over time?
E.g., Hole depth, number of customers waiting in line, coffee temperature, etc. It needs to be a measurable variable that has a range of acceptability.
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Which “time” attributes on the chart shown above are out of control?
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What does this out-of-control condition mean for the variable you have chosen?
E.g., If a dot is out of control for the variable of coffee temperature, that would mean that the coffee is too hot to drink.
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Perform five-why root cause analysis to determine why the variable is out of control:
Why is the variable out of control? Add text
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What containment actions will you put in place to prevent further injury, damage, or propagation of the out-of-control condition? These are actions to “rope off” or secure the situation.
E.g., Set aside coffee that is too hot to drink and do not allow it to be served to customers.
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What corrections will you make to the out-of-control condition to get it back into control? This can be rework, scrap and replace, etc.
E.g., Add an ice cube to the extra hot coffee and leave it aside until it is cool enough to drink. Adjust temperature setting on coffee pot so the next batch of coffee does not come out as hot when it is ready.
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What corrective action will you take to minimize the likelihood that the variable will go out of control again? This can be procedural change, training content change, engineering control put in place, design change, administrative control, equipment change, etc.
E.g., Tape down the temperature setting knob on the coffee pot so it does not get bumped out of position again.
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