DMAIC Phases: Control

After weeks (or even months) of analyzing data, identifying root causes, and implementing improvements, you’ve finally reached the DMAIC Phase: Control. But don’t be fooled—this isn’t the time to coast. The Control phase is where your hard-earned improvements are locked in, sustained, and scaled. It’s the difference between a temporary fix and a lasting transformation.

Let’s dive into what makes this phase so critical—and how to do it right.

Why the Control Phase Matters

Imagine spending months improving a process, only to watch it slowly revert to its old, inefficient ways. That’s what happens when the Control phase is skipped or rushed. The goal here is simple: make sure the improvements stick.

Control is about:

• Monitoring performance to ensure gains are maintained.
• Standardizing processes so everyone follows the new way of working.
• Responding quickly if performance starts to slip.

In short, Control is the safety net that protects your project from backsliding.

Key Elements of the Control Phase

1. Control Plan

Think of this as your playbook for sustaining success. A Control Plan outlines:

• What metrics will be monitored
• Who is responsible for monitoring
• How often data will be reviewed
• What actions to take if performance dips

It’s not just a document—it’s a commitment to vigilance.

2. Standard Operating Procedures (SOPs)

Once a new process is working, it needs to be documented clearly and concisely. SOPs ensure that everyone—from new hires to seasoned employees—knows exactly what to do and how to do it.

Tip: Use visuals like flowcharts or checklists to make SOPs more user-friendly.

3. Training and Communication

Even the best process won’t succeed if people aren’t on board. That’s why training is essential. Make sure everyone understands:

• What’s changing
• Why it’s changing
• How it benefits them and the organization

Clear, consistent communication builds buy-in and reduces resistance.

4. Visual Management

Visual tools like dashboards, control charts, and performance boards make it easy to spot trends and take action. They also promote transparency and accountability.

For example, a simple control chart can show whether a process is staying within acceptable limits—or drifting off course.

5. Response Plan

What happens if things go wrong? A good Control phase includes a response plan that outlines:

• Early warning signs of trouble
• Who to notify
• What corrective actions to take

This proactive approach prevents small issues from becoming big problems.

Tools Commonly Used in the Control Phase

• Control Charts: Track process stability over time.
• Check Sheets: Collect real-time data on process performance.
• Mistake-Proofing (Poka-Yoke): Design processes to prevent errors.
• Audits: Ensure compliance with new standards.
• Dashboards: Provide real-time visibility into key metrics.

Each tool plays a role in reinforcing the improvements made during the Improve phase.

Real-World Example: Control in Action

Let’s say a hospital reduced patient wait times by streamlining its triage process. During the Control phase, they:

• Created a dashboard to track average wait times daily
• Updated SOPs for triage nurses
• Trained staff on the new workflow
• Set up weekly audits to ensure compliance
• Developed a response plan for when wait times exceeded targets

The result? Sustained improvement and a better patient experience.

Tips for a Successful Control Phase

• Involve frontline staff in developing control mechanisms—they’re closest to the work.
• Celebrate wins to reinforce positive behavior.
• Keep it simple—overly complex controls are less likely to be followed.
• Review and refine—Control isn’t a one-and-done effort. Revisit your plan periodically.

Final Thoughts

The Control phase may not be as flashy as Improve or as analytical as Analyze, but it’s the glue that holds your project together. It ensures that your Lean Six Sigma efforts deliver long-term value—not just short-term gains.

So as you wrap up your DMAIC project, don’t just ask, “Did we fix the problem?” Ask, “How will we make sure it stays fixed?”

That’s the essence of Control—and the key to continuous improvement.

If you’re interested in learning more about how to use DMAIC, consider enrolling in Leanademy’s Training classes.

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