Control Phase Blog
The Control stage is the final stage of the DMAIC process. For the purpose of this this project the Control Phase will include the following; an outline of how the process will be controlled, how ongoing compliance will be achieved, an early review of the effectiveness of the process improvements via control charts and by comparing metrics before and after improvements. a project of savings achieved will also be included in the final report.
A P-Chart will be used to control the process. The data will be gathered by the team members on the line, these data sheets are collected by the production administrator and inputted into an Excel spreadsheet, this data is automatically generated into a P-chart as it is inputted. This P-Chart can be reviewed at any time by the Production Manager. After implementation of the changes a review will be carried out weekly by the team leader (me). This review will continue for a significant period of time into the future.
The Table below was taken from the Measure phase and updated to include the metrics after the improvements were implemented.
The Table below was taken from the Measure phase and updated to include the metrics after the improvements were implemented.
%Rejects before improve
|
%Rejects after improve
|
Rejects before improve
|
Rejects after improve *
|
DPMO before improve
|
DPMO after improve*
|
Yield before improve
|
Yield after improve*
|
s Level before improve
|
s
Level before improve*
|
|
P 1
|
8%
|
6.6%
|
5,010
|
2,464
|
531
|
198
|
99.58%
|
99.84%
|
4.7s
|
5.04s
|
P 2
|
47%
|
40%
|
27,823
|
14,916
|
2947
|
1195
|
97.64%
|
99.04%
|
4.2s
|
4.54s
|
P 3
|
45%
|
53.4%
|
26,502
|
19,910
|
2807
|
1595
|
97.75%
|
98.72%
|
4.2s
|
4.45s
|
T
|
100%
|
100%
|
59,335
|
37,290
|
6285
|
2988
|
94.97%
|
97.61%
|
3.9s
|
4.25s
|
* Signifies a projection of results based on the data gathered since the implementation of the improve phase. The implementation of the improve phase was the 1st of April 2016.
"Objective Statement - Reduce the DPMO to <3140 within 6 months, to do this scrap must be reduced by 50%. This is around 2,472 rejects p/m. If a DPMO of 3140 is achieved; this will allow a sigma level of 4.2 to be achieved."
When we compare our projected metrics from the table to our Objective Statement, we appear to be well on track to achieve our target. However we must not get ahead of ourselves, the metrics in the table are projections from the 1st - 14th of April 2016. The imperative part of this project is now to control and maintain or improve upon these early results.
"Objective Statement - Reduce the DPMO to <3140 within 6 months, to do this scrap must be reduced by 50%. This is around 2,472 rejects p/m. If a DPMO of 3140 is achieved; this will allow a sigma level of 4.2 to be achieved."
When we compare our projected metrics from the table to our Objective Statement, we appear to be well on track to achieve our target. However we must not get ahead of ourselves, the metrics in the table are projections from the 1st - 14th of April 2016. The imperative part of this project is now to control and maintain or improve upon these early results.
The addition of the visual inspection system will save between 0.8 - 2 operators per annum after introduction. A projection of savings for the year will be included in the control phase of the final report. This projection will allow for savings with and without the vision system.
Taking part in this project has been a great experience for the team, as mentioned in the improve phase a DOE was set up for process two. This DOE will form the basis of a new project, with the aim of again halving the DPMO for process two. This project stems directly from the ground work during this project.
Overall this project can be deemed a success so far, the report shall outline the achieved results in more detail and over a greater length of time i.e. 1st - 28th of April, this will allow for more accurate projections.
