Statistical Process Control & Process Capability

Course Overview

This course is a great place to learn about what really drives product quality and how to monitor processes to pro-actively drive quality improvement. Participants gain the fundamental knowledge necessary to implement Statistical Process Control and learn to avoid the common mis-applications in practice. Knowledge of basic algebra is helpful but not required.

The objective of the SPC/Process Capability  curriculum is to provide participants with the analytical tools and methods necessary to:

Course Objective

  • Understand SPC fundamentals and the importance of reducing variation
  • Implement control charting in order to assess process stability
  • Interpret control chart signals and implement appropriate reaction plans
  • Determine appropriate sampling plans and sample sizes
  • Assess process capability (for normal and non-normal data)
  • Apply charting techniques for short production runs
  • Apply charting methods where multiple sources of variation may exist (e.g. multiple cavities, filling heads)
  • Apply SPC for naturally trending data (e.g. due to tool wear)
  • Determine the appropriate type of chart for a given process
  • Avoid common misapplications of SPC in practice

Seminar Content

  1. Variation Fundamentals
    • Concept of Variation
    • The Normal Distribution
    • Control Chart Concepts/Examples
    • Control Limits vs. Specification Limits
    • Definition of Control/Stability
    • Definition of Quality
    • Sources of Variation
    • Process Capability Concepts
    • Quality Control vs. Process Control
    • Basic Statistics
    • Individuals, Averages, and the Central Limit Theorem
  2. Control Charts
    • Constructing Charts (Variable Data)
    • Xbar/R , Xbar/S, I-MR Charts
    • Chart Signals for Special Causes
    • Interpreting Charts
    • Type I and Type II Errors
    • Recomputing Control Limits
    • Sampling Procedures and Frequency
    • Rational Samples
    • Chart Sensitivity / Sample Size
    • Determining Appropriate Sample Sizes
    • Control Chart Selection
  3. Process Capability
    • Stability vs. Capability
    • Types of Capability Assessments
    • Estimating PPM / Proportion Defective
    • The Standard Normal (Z Values)
    • Capability Indices: Cp, Cpk, Pp, Ppk
    • Interpreting Indices
    • Process Capability for Non-Normal Data (Overview)
  4. Specialized Charts
    • Short Run Charts
    • Within/Between Charts (Multiple Locations)
    • CUSUM Charts
    • Trending Charts
    • Charts for Attribute Data