Statistical Process Control (SPC) Plan for the SuperNova School Project -

Control Phase
Six Sigma Black Belt Master Expert Perspective

The Control Phase of the Six Sigma methodology is vital for ensuring that the improvements
made in the earlier phases of the SuperNova School project are sustainable and that the processes
are kept in a state of statistical control. Statistical Process Control (SPC) is a tool used in this
phase to monitor the stability and capability of key processes to prevent variations from affecting
the project’s goals and deliverables.

SPC is essential for monitoring and controlling processes such as student admissions, classroom
setup, facilities management, and educational delivery. By utilizing SPC, we can identify any
deviation from the desired performance early on and take corrective actions promptly, ensuring
that the processes remain within acceptable limits and continue to meet the objectives.

Objective of SPC in the Control Phase:

The primary objective of applying SPC to the SuperNova School project during the Control Phase is to:

1. Monitor Process Stability: Ensure that all processes involved in school operations are stable and
performing consistently.

2. Identify Variations: Detect any deviations or outliers in key processes (such as student
satisfaction, classroom attendance, and facilities uptime) that may impact the project’s
performance.

3. Enable Proactive Interventions: Utilize SPC tools to detect issues early, allowing for prompt
corrective actions before they escalate.

4. Sustain Improvements: Ensure that process improvements made during the previous phases are
maintained and do not regress over time.

SPC Tools to be Used:

Several SPC tools will be employed to measure, monitor, and control process variations. These tools are
designed to analyze and visualize data on key processes and will help keep the project on track.

1. Control Charts:

o Purpose: Control charts are used to track process performance over time. They will be
applied to monitor key variables such as:

 Student Admission Time: Time taken for the entire student admission process.

 Classroom Setup Time: Time taken to prepare classrooms for sessions.

 Facilities Maintenance Response Time: Time taken to resolve maintenance

issues.

 Student Satisfaction Scores: Measurement of student feedback and satisfaction

levels.

o Types of Control Charts to Use:

 X-bar and R-Chart: For monitoring the mean and range of continuous data such
as response times for maintenance or classroom preparation.

 P-Chart (Proportion Chart): For monitoring the proportion of defective or

dissatisfied students based on feedback surveys.

 C-Chart: For counting the number of defects, such as the number of

maintenance issues or delays in classroom setup.

2. Process Capability Indices (Cp, Cpk):

o Purpose: These indices will be used to evaluate the capability of key processes to meet
specifications and identify whether the processes are capable of performing within set
limits.

o Application: For example, evaluating whether the student admission process consistently
operates within the required time frame or whether the maintenance response times are
consistently within the acceptable range.

3. Pareto Analysis:
 o Purpose: Pareto Analysis will be used to identify the "vital few" factors contributing to
the majority of process problems or variations. This will enable the team to prioritize
interventions.

o Application: Identifying the most common causes of delays in classroom setup, the
highest areas of dissatisfaction among students, or the maintenance issues that occur most
frequently.

4. Scatter Diagrams and Trend Analysis:

o Purpose: These tools will be used to visually identify relationships between different
process variables (e.g., relationship between maintenance response time and student
satisfaction).

o Application: If a pattern is identified indicating that slower maintenance response times

correlate with lower student satisfaction, this relationship can be addressed in the
improvement plan.

Key Performance Indicators (KPIs) for Monitoring:

The following KPIs will be monitored using SPC tools to ensure the SuperNova School project remains
within acceptable control limits:

1. Student Admission Process:

o Average time taken for student admission.

o Percentage of students admitted within the target time.

o Variability in admission times.

2. Classroom Setup Time:

o Average time taken to prepare classrooms.

o Percentage of classrooms set up within the target time.

o Variability in classroom setup times.

3. Facilities Maintenance Response Time:

 o Average time taken to resolve maintenance issues.

o Percentage of maintenance issues resolved within a specific time frame.

o Frequency of maintenance issues.

4. Student Satisfaction:

o Average student satisfaction score (on a 5-point scale).

o Percentage of students satisfied with facilities, teaching quality, and overall school
experience.

o Trends in satisfaction over time.

SPC Monitoring and Control Plan:

SPC
Action Plan for Out-of- Responsible
Process Area Tool Control Limits Frequency
Control Conditions Person
Used

Student Upper: 120

X-bar & Investigate causes of delay, Admissions
Admission mins, Lower: 60 Daily
R-Chart improve process efficiency Manager
Process mins

Implement standardized
Classroom Setup X-bar & Upper: 30 mins, Facilities
setup procedures and Daily
Time R-Chart Lower: 10 mins Manager
training

Accelerate response times

Facilities X-bar & Upper: 4 hrs, Maintenance
through additional staff or Weekly
Maintenance R-Chart Lower: 1 hr Supervisor
training

Student Upper: 90%, Conduct root cause analysis

P-Chart School Director Monthly
Satisfaction Lower: 80% on low satisfaction areas

SPC Process for Control and Action:

 1. Monitor: Data will be collected continuously (daily or weekly depending on the process) and
analyzed using the above SPC tools.

2. Analyze: The collected data will be plotted on the control charts. If any data points fall outside
the established control limits, the process will be flagged as “out-of-control.”

3. Identify Root Causes: For any out-of-control situations, a root cause analysis will be conducted
(using tools like Fishbone diagrams or 5 Whys) to identify the underlying issues causing the
variation.

4. Corrective Actions: Based on the root cause analysis, corrective actions will be taken to bring
the process back into control. This may involve retraining staff, modifying workflows, or adding
resources to address capacity issues.

5. Review: The control charts and process capability indices will be reviewed regularly to assess
whether the corrective actions were effective and whether additional adjustments are necessary.

SPC Reporting:

 Daily Reports: Control charts for key processes (e.g., student admission times, classroom setup)
will be reviewed and reported daily to the project team to ensure no deviations occur.

 Weekly Reports: A summary of key SPC findings, including process capability analysis, will be
provided to leadership to ensure they are informed of any significant process variations.

 Monthly Review: A comprehensive monthly review of all SPC data will be conducted to assess
overall process performance, and corrective actions will be adjusted accordingly.