Best strategies for sustaining gains after a Six Sigma project enters the Control phase?

All answers to this question.

Sustaining gains is 20% tools and 80% culture. While Statistical Process Control (SPC) is necessary, you should implement "Poka-Yoke" (error-proofing) wherever possible. If the new process is physically or digitally designed so that it’s impossible to do it the "old way," you don’t have to worry about drift. In late 2023, we added mandatory fields in our ERP system that matched the new Six Sigma workflow. The users literally couldn't revert. Additionally, you must integrate the project KPIs into the process owner's annual performance review. If their bonus depends on the Six Sigma metrics, they will find a way to maintain them.

   Answered 2024-01-18 by Margaret Fisher

Have you considered a "Reaction Plan" as part of your Control document? Most people have a chart but don't know what to do when a point goes out of control. Does your current documentation clearly define who is contacted and what immediate action is taken when a "special cause" variation is detected on your control charts?

   Answered 2024-01-20 by Richard Moore

• Richard, we actually lack a formal Reaction Plan. We have the charts, but the operators usually just ignore the red dots or "wait and see." Based on your question, I’m going to create a tiered response matrix: Tier 1 is operator adjustment, Tier 2 is supervisor notification, and Tier 3 is an engineering hold. This should provide the clear "what now" that our current Control phase is missing.

     Commented 2024-01-22 by Jennifer Lewis

Use "Audit Layers." Have the manager check the process once a week, and the director check once a month. This visual management keeps everyone's attention focused on the new standard.

   Answered 2024-01-23 by Sarah Jenkins

• Auditing is key. I’ve seen the "Layered Process Audit" (LPA) work wonders in manufacturing. It keeps the accountability moving up the chain, exactly as Sarah suggested.

     Commented 2024-01-24 by Margaret Fisher