How to Use a Control Plan for Six Sigma

Two business people, one man and one woman, both looking at a clipboard together with two other businessmen in the background shaking hands, and there is a banner across the bottom of the image that reads "Six Sigma Control Plan".

Last Updated October 19, 2023

No project can be considered complete until it is supported by a control plan. By the final stages of a Six Sigma project, your team has solved the major problems in the specified process. Make sure the problems remain solved with safeguards that keep the improved process functioning as your team intended. A process control plan provides these safeguards.

The heart of the control plan is detailed documentation describing how the new process functions. This documentation acts as the standard of comparison by which the process is continually monitored and evaluated to ensure that its actual operations are not straying too far from the way it was designed by the project team.

A good control plan is based on a carefully designed strategy. This strategy should reduce the number of changes leadership needs to make to the process by plainly stating what corrective actions are necessary when the process begins to operate outside established parameters. The control plan should also state training requirements and maintenance schedules for equipment, where required.

Control Plan Documentation

A Six Sigma control plan can be displayed on a simple table. A typical process control plan can contain six sections that record essential process details.

Administrative

This section of the plan records key information to identify the process and the process owner. It also displays the revision level to identify which iteration of the plan it is.

Operational Definition

This column gives the team a chance to explain how the process adds value. It helps provide context for the process.

Subject of Control

This section describes what is being controlled. It is displayed in several separate columns.

Process Number – This is the process step identified by a number that locates it on the process flow chart.
Process Description – Provides a simple description of the process.
Machines – The control plan lists any devices used in the production process.

Characteristics

Control plans usually monitor product and process characteristics.

Product characteristic – This is an attribute of the product that must meet the control standard. For example, in a process manufacturing pencils, this is the length of the pencil.
Process characteristic – This is a standard that the process must meet as part of the control plan. Such as properly placing parts or accurately transferring a phone call.

Control Methods

These are the tools used to monitor the process to determine if it is performing properly. They can include checklists and statistical process controls.

Standard Operating Procedures

This section contains links to instructional documents that help explain how to maintain your new process.

A detailed control plan can help you rest easy as you conclude the Six Sigma project knowing that the improved process will likely remain on its new, improved level of performance.