A-B Control - Lean Six Sigma Glossary

A-B control, also known as split-run testing, is a process control method used in manufacturing to compare the performance of two different processes or process settings. The method involves running one process (A) and another process (B) in parallel and comparing the results to determine which is more effective in terms of quality, efficiency, and cost.

Applications of A-B Control

A-B control is used in a variety of manufacturing industries and applications, including:

Machine settings: It is used to compare different machine settings to determine which settings produce the best quality and efficiency.
Materials: A-B control is used to compare different materials or suppliers to determine which materials produce the best quality and lowest cost.
Processes: It is used to compare different manufacturing processes to determine which process is the most efficient and produces the best quality.

A-B Control as a process control method in Manufacturing

It is also used in manufacturing as a process control method. Here, multiple sequential machines are synchronised so that if one machine stops, the machines that come after it in the production process also stop. This method is used to improve efficiency and reduce waste by ensuring that all machines are operating correctly and at optimal levels.

The A-B Control process typically involves several steps:

Define the process: The first step is to clearly define the process, including the key characteristics or variables that will be monitored. This step is important to ensure that the correct data is being collected and analysed.

Establish the A-B Control system: The next step is to establish the A-B Control system by linking the machines in the production process. This can be done by using sensors or other monitoring devices to detect when one machine has stopped and then sending a signal to the machines that come after it in the production process to also stop.

Monitor the machines: Once the A-B Control system is established, the next step is to monitor the machines in the production process to ensure that they are all operating correctly and at optimal levels. This can be done by using sensors or other monitoring devices to detect any issues or variations in the production process.

Take action: If a problem is identified, the next step is to take action to address the issue. This may involve making adjustments to the process, implementing corrective actions, or conducting further analysis to determine the root cause of the problem. Monitor and adjust: After taking action, it is important to continue monitoring the process and making adjustments as needed to maintain control and prevent recurrence of the problem.

Advantages of A-B Control

The method is highly effective in improving efficiency and reducing waste in the production process. By ensuring that all machines are operating correctly and at optimal levels, organizations can improve production efficiency and minimize downtime. Additionally, the A-B control method is useful in maintaining the integrity and order of production process, it also helps in creating an efficient system that can identify the problem and stop it in the earliest possible time.

Limitations

A-B control also has some limitations in manufacturing, including:

Time-consuming: It can be time-consuming as it requires running two processes in parallel.
Limited scope: It only compares two processes or settings, so it may not be appropriate for testing multiple variations.
External factors: A-B control may not take into account external factors that may affect the performance of the two processes, such as changes in market demand or technology.

By the way, do check out the Certified Lean Six Sigma Black Belt Handbook – it is one of the most essential guide for anyone trying to get certified as LSS Black belt or in general wants to understand LSS and improve processes. – check it out here.

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Sachin Naik

Passionate about improving processes and systems | Lean Six Sigma practitioner, trainer and coach for 14+ years consulting giant corporations and fortune 500 companies on Operational Excellence | Start-up enthusiast | Change Management and Design Thinking student | Love to ride and drive