How do you troubleshoot and resolve issues or problems detected by control charts?

Process Control Charts 101 What you need to know … First you need a control plan. If you don’t have one or don’t know what one is, that’s step 1 (understanding control charts) and step 2 (creating control charts). To elaborate, you need to: 1) understand control plans 2) what they are used for 3) why they are used 4) who should build them 5) who should use them AND how they should use them Key Takeaways … - A "Process Owner" should be identified to own the control plan. - The control plan should articulate to the process owner, what to do in various scenarios in terms of how to investigate points outside the upper and or lower control limits and after investigation, what to do (if anything) following your investigation.

Understand the Control Chart Signals: Familiarize yourself with the various signals or patterns that control charts can indicate, such as trends, shifts, cycles, or out-of-control points. Determine the type of signal detected by the control chart and its significance in relation to the process performance. Gather Data and Context: Collect relevant data and information related to the observed issue or problem detected by the control chart. Consider factors such as process inputs, equipment settings, operating conditions, environmental factors, and any recent changes or events that may have influenced process performance.

To troubleshoot control chart issues we have to investigate points outside control limits. We can do that by using data analysis tools to identify potential root causes & implement corrective actions to address identified issues. We should also monitor process performance to assess the effectiveness of corrective actions & update control limits as needed to reflect process changes. As a recurring activity we should continuously analyze control chart data to prevent future problems & by adhering to these steps i am sure we can effectively use control charts for process improvement.

The third step is to identify and verify the root causes of the problem. Dig deeper into the factors identified previously to determine why they cause the issue. Use tools like the 5 Whys, cause-and-effect matrix, FMEA, or hypothesis testing to confirm and validate these causes with data and evidence. The goal is to establish a clear causal relationship between the factors and the problem.

Generate Solutions: Use brainstorming and affinity diagrams to come up with potential solutions. Select Solutions: Apply multicriteria decision analysis or cost-benefit analysis to choose the best options. Implementation: Execute the chosen solutions to address root causes. Evaluation: Assess the effectiveness and sustainability of the solutions. Goal Alignment: Ensure solutions meet project objectives and stakeholder expectations.