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09 - Control - ESTIEM Lean Six Sigma Green Belt Course

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These slides are part of the ESTIEM Lean Six Sigma Green Belt course which also includes 13hr of video by Gregory H. Watson.
For more info about the ESTIEM Lean Six Sigma Green Belt course visit https://internal.estiem.org/leansixsigma

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09 - Control - ESTIEM Lean Six Sigma Green Belt Course

  1. 1. European Students of Industrial Engineering and Management www.estiem.org Control for publication 1
  2. 2. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! 2 Persons giving feedback Link to the feedback form (can be found on Schoology and WhatsApp) Instructor to give feedback toPersons giving feedback INSTRUCTOR 1 INSTRUCTOR 2
  3. 3. European Students of Industrial Engineering and Management www.estiem.org Time to go to the Control phase. What is the purpose of the Control phase? 3
  4. 4. European Students of Industrial Engineering and Management www.estiem.org Achieving real change in processes is difficult You as a GB, should help the process owner to manage the implementation 4
  5. 5. European Students of Industrial Engineering and Management www.estiem.org “Control activities create a standard way of working and “hold the gains” from the project improvement activities.” Control is a fundamental requirement for routine work! 5
  6. 6. European Students of Industrial Engineering and Management www.estiem.org Incremental improvement achieves a local maximum Time Progress in Effectiveness Continual Improvement Designed Process Capability (Cp) Waste, Loss, Inefficiency 6
  7. 7. European Students of Industrial Engineering and Management www.estiem.org Capability improvement is “designed” into systems Time Progress in Effectiveness Breakthrough Stagnation CP1 CP2 CP3 CP4 7
  8. 8. European Students of Industrial Engineering and Management www.estiem.org An integrated approach to systemic improvement Time Progress in Effectiveness Breakthrough New baseline Maximum for CP1 Maximum for CP2 New baseline New baseline Multiplying effect of combining incremental and breakthrough improvements. Continual Improvement 8
  9. 9. European Students of Industrial Engineering and Management www.estiem.org In the Control phase, the workers are engaged when using following methods Documenting standard work Mistake-proofing Statistical control 9
  10. 10. European Students of Industrial Engineering and Management www.estiem.org Why should the standard work be documented? Documenting standard work Mistake-proofing Statistical control 10
  11. 11. European Students of Industrial Engineering and Management www.estiem.org People tend to do the things differently – some ways are more optimal than others. Without standards, there can be no improvement. Documenting standard work Mistake-proofing Statistical control 11
  12. 12. European Students of Industrial Engineering and Management www.estiem.org Documenting standard work Mistake-proofing Statistical control What is the purpose of mistake-proofing? 12
  13. 13. European Students of Industrial Engineering and Management www.estiem.org Catching mistakes and errors before they turn into defects! Documenting standard work Mistake-proofing Statistical control 13
  14. 14. European Students of Industrial Engineering and Management www.estiem.org Documenting standard work Mistake-proofing Statistical control Mistakes – within people Errors – within process Defects – outside factory Don’t let defects escape the factory! 14
  15. 15. European Students of Industrial Engineering and Management www.estiem.org Control charts can be used to monitor the process performance Documenting standard work Mistake-proofing Statistical control 15
  16. 16. European Students of Industrial Engineering and Management www.estiem.org Which control chart you would use to monitor a process and why? Documenting standard work Mistake-proofing Statistical control 16
  17. 17. European Students of Industrial Engineering and Management www.estiem.org Documenting standard work Mistake-proofing Statistical control Which one gives you more information? – Data is the same 17
  18. 18. European Students of Industrial Engineering and Management www.estiem.org Documenting standard work Mistake-proofing Statistical control Which one gives you more information? – Data is the same 18
  19. 19. European Students of Industrial Engineering and Management www.estiem.org Documenting standard work Mistake-proofing Statistical control Which one gives you more information? – Data is the same 19
  20. 20. European Students of Industrial Engineering and Management www.estiem.org In the Control phase, the usage of 4 methods is highly recommended for the success Implementation plan Realization review Control plan Benefit Capture plan 20
  21. 21. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan What is the purpose of implementation plan? 21
  22. 22. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan Defines improvement activities, accountable persons for each activity, and targets for improvement 22
  23. 23. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan 23
  24. 24. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan What is the purpose of control plan? 24
  25. 25. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan Defines key process outputs, measurements to control the outputs, and responses to abnormal situations 25
  26. 26. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan 26
  27. 27. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan What is the purpose of realization review? 27
  28. 28. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan One page executive summary done in the end of the project, describing the main findings of the projects 28
  29. 29. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan Can contain AchievedBaselineProcess Capability AchievedBaselineCost of Poor Quality AchievedBaseline Achieved Productivity (Cycle Time) Project charter information Budget Reduction Taken by Cost Center (Approvals) Lessons Learned –Follow-on Projects Identified Further Savings Leverage Opportunities Identified 29
  30. 30. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan What is the purpose of benefit capture plan? 30
  31. 31. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan Monitor execution of planned improvements and report on benefits received by these improvements 31
  32. 32. European Students of Industrial Engineering and Management www.estiem.org Implementation plan Realization review Control plan Benefit capture plan Responsibility accepted by a line manager/supervisor Baseline Measure Monitored Performance Measure Identification of improvement opportunity Achievable Performance Target Expected Financial Benefit Achieved Completion Date Percentage of Task Completion Financial Benefit Achieved (by financial department) Additional Improvement Available 32
  33. 33. European Students of Industrial Engineering and Management www.estiem.org All the previous methods are performed by a Green Belt. What is the reason of making them? Ensuring the implementation of changes and smooth transition to daily management 33
  34. 34. European Students of Industrial Engineering and Management www.estiem.org The implementation of changes and controlling the process is the job of process owner. Your help will be needed! 34
  35. 35. European Students of Industrial Engineering and Management www.estiem.org Questions & comments? 35
  36. 36. European Students of Industrial Engineering and Management www.estiem.org How important is the Control phase? 36
  37. 37. European Students of Industrial Engineering and Management www.estiem.org Remember these? - which one do you want? 37
  38. 38. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! 38 Persons giving feedback Link to the feedback form (can be found on Schoology and WhatsApp) Instructor to give feedback toPersons giving feedback INSTRUCTOR 1 INSTRUCTOR 2
  39. 39. European Students of Industrial Engineering and Management www.estiem.org It’s Feedback time! Feedback box 39
  40. 40. European Students of Industrial Engineering and Management www.estiem.org Usage license of the materials https://creativecommons.org/licenses/by-nc/4.0/legalcode Contact leansixsigma@estiem.org for commercial usage of the materials Materials of the trainings have been created based on the materials provided by ESTIEM Summer Academy Professor Gregory H. Watson

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