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When a Lean Six Sigma project reaches the Control phase , many teams feel a sense of victory. The improvements are showing results, variation is down, and processes are running smoothly. But here’s the reality — without a solid control and response plan, those hard-earned gains can fade fast . A well-designed Control Plan  and Response Plan  ensure that the new process not only sustains improvement but also alerts you when things start to drift. Let’s explore how to build one

In Lean Six Sigma, one of the most powerful tools for monitoring process performance and maintaining improvements is the control chart . These charts help teams distinguish between common cause variation (the natural fluctuation in a process) and special cause variation (unexpected shifts caused by specific factors). By visualizing data over time, control charts provide the evidence needed to make better decisions, prevent overreaction, and ensure processes remain stable. But

You've defined the problem. Measured the process. Analyzed root causes. Improved the performance. Now what? Welcome to the Control Phase —the final step in the DMAIC (Define–Measure–Analyze–Improve–Control) cycle. Often underestimated, this phase is where the real test begins : can your team sustain the improvements  over time? In this post, we'll explore how to effectively execute the Control phase, what tools to use, and how to keep your hard-earned results from slipping ba