Quality Management & Training

STATISTICAL PROCESS CONTROL (SPC)

To prosper in today’s economic climate it is essential that all quality processes are evaluated in a manner that will ensure continuous improvements in both quality and productivity. Quality professionals already understand the importance of taking action before rejects or defective items are produced, or if rectification is necessary – thus avoiding unnecessary expense and halting of production with all its inherent problems. Most quality systems also implement a safety scheme in the form of sampling schemes at the goods inward stage, as protection for the consumer. For such schemes to operate satisfactorily, and efficiently, a knowledge of the underlying principles is essential.

Properly applied statistical control can prevent problems and lead to: Continuous Improvement in product quality Improved productivity and reduced overtime Operator involvement and commitment to improving quality. Reduced rejects, Rectification, test and inspection costs Reduce the occurrences of defective goods getting past the goods inwards stage.

Statistical Process Control (SPC) is used for the purposes of process qualification, problem solving, process monitoring, and continual improvement.

SPC is applicable to a wide range of process situations, where data is used to understand and manage the performance of manufacturing and non-manufacturing processes.

SPC is one of the key ‘core tools’.  ‘Core Tools’ are defined as the five supplemental techniques and methods which support the expectations of IATF 16949 (see links below):

Advanced Product Quality Planning (APQP)

Failure Mode and Effects Analysis (FMEA)

Measurement Systems Analysis (MSA)

Statistical Process Control (SPC)

Production Part Approval Process (PPAP)

The above courses can be delivered individually or as a consolidated programme of training.

BUSINESS BENEFITS

  • Establishes process control and process capability prior to the start of serial production
  • Enables the future performance of a process to be predicted
  • Emphasises defect prevention and continual improvement
  • Facilitates ongoing analysis and monitoring of process performance
  • Provides an early indication when abnormal process conditions occur, enabling appropriate action to be taken
  • Supports a risk-based approach and requirements of quality management systems, e.g. IATF 16949
  • Assists an organisation to consistently satisfy customer requirements

WHO SHOULD ATTEND?

This course is appropriate for all personnel who are involved in the collection, analysis, auditing, and management of statistical data, including:

  • SPC facilitators
  • Process managers and engineers
  • Quality engineers
  • Team leaders and process personnel
  • Laboratory technicians
  • Internal quality auditors
  • Data analysts
  • Continual improvement practitioners

COURSE OBJECTIVES

The delegates should understand:

  • Basic statistical concepts
  • Common and special causes of variation
  • How to create and interpret a control chart
  • Process capability and performance
  • How SPC methods are used to control and improve a process to ensure that customer requirements are satisfied
  • The linkage with quality management requirements, e.g. IATF 16949, APQP / PPAP

On completion of the course, delegates will be a QM&T validated and certificated SPC practitioner.

COURSE STRUCTURE

Introduction to SPC

  • Sources of variation in a process
  • Limitations of inspection and test methods
  • Basic statistics
  • Collection and analysis of data
  • Understanding process variation through data

Control Charts for Variables

  • X-bar and XmR control charts
  • Calculating control limits for variables charts
  • Common and special causes
  • Decision rules, and interpretation of control charts

Control Charts for Attributes

  • p, np, c and u charts
  • Laney control charts

Managing Control Charts

  • Selecting an appropriate control chart
  • Setting up and maintaining a control chart

Process Performance and Capability

  • Capability and performance indices (Cp; Cpk, Pp, Ppk)
  • Predicting process fallout
  • Capability vs control

 

COURSE DATES AND COST

See Training Courses for price list and order form