Statistical Process Control (SPC)

Introduction

Manufacturing Organizations use SPC tools to drive continual improvement in Manufacturing and Production Operations. In the present work environment everyone involved in continual improvement should be equipped or armed with the know how in utilizing SPC tools. This course will improve the analytic skill and effectiveness in monitoring process performances. And implementation of the appropriate countermeasure when process deviates from target. Also determine the process capability.

Objective

1. The ultimate goal of every manufacturing company is to achieve total customer satisfaction. One of the key initiatives in achieving this goal is through the introduction of Statistical Process Control (SPC)
2. The understanding of variation, its source and how to control the  variation is the fundamental in making sure that the manufacturing process is stable. Through the introduction of statistical process control (SPC), it will prompt the user when there is out of control situation
3. This course will introduce the participants to basic understanding of statistic, perform hand–on measurement system analysis, conduct    process capability study and establish an effective Statistical Process Control (SPC) program
4. The program aims to :

• Describe the overall concepts of variation to the process, fundamental statistics and measurement system
• Describe the key elements and importance of an effective Statistical    Process Control (SPC) program
• Construct control charts for variables data (X-bar-R, and X-mR) and    attribute charts (p, np, c, and u)
• Outline the steps in implementing and maintaining the SPC program
• Where you can and cannot use X bar R Charts

Course Content

1. Working with variation

-  Accuracy

-  Precision

-  The Standard Deviation

-  Calculating the Standard Deviation

-  The Excel Formulas

-  The Histogram

-  The Normal Distribution

-  The Bell Shaped Curve

-  Calculating the Area

-  Normal Distribution Tables

-  Finding the Z Score

-  Common and Special Causes

-  The Range Method

-  Variation Exercises

2. Process capability

-  The Foundation of Capability

-  Natural Tolerance Limits

-  Cp Process Capability Index

-  Interpreting Cp

-  Cpk Process Capability Index

-  Upper and Lower Process Capability Index

-  Pp, Ppk Process Performance Index

-  Non-Normal Distributions

-  The Six Sigma Metrics

3. Control charts for variables

-  Run Charts

-  Control Charts for the Mean

-  Why Take Subgroups?

-  Sample vs Process Standard Deviations

-  The Significance of Control Limits

-  Calculating the Control Limits

-  Introducing A2

-  Control Charts for the Range

-  Control Chart Design

-  Control Charts Example

-  Type I and II Errors

-  The Probability of a Type II Error

-  Interpreting Patterns

-  Distribution of Points

-  Applying Control Charts for Variables

4. Control charts for attributes

-  The Standard Deviation

-  The Control Limits

-  np Charts

-  p Charts

-  Varying Control Limits

-  p Chart example

-  c Charts

-  c Charts Examples

-  u-Charts

Target Audience

Technicians, Supervisors, Executives, Quality & Manufacturing Engineers, Maintenance Engineers, and Management Personnel who are involved in continuous improvement activities