BASIC STATISTICAL PROCESS CONTROL
(SPC) - 3 DAYS
J.G. Noguera & Associates
Statistical process control assures that
processes operate in a state of statistical control. All special causes of
variability are distinguished from common random occurrences and are
eliminated. Products can then be manufactured with consistently high quality.
About the Seminar:
This seminar not only emphasizes the tools
and techniques of SPC - it also provides training in the problem-solving
methods and teamwork needed to utilize these tools effectively. In addition to
manual implementation, students will learn how to use SPC software for
problem-solving, control charts, and process capability analysis. Participants
gain hands-on experience with actual industrial examples, use of the Quincunx
(Bead Board - shown below), and computer simulations.
This seminar is designed to be flexible with
topics emphasized or de-emphasized according to customer needs. Client data may
be included in the examples and exercises.
Quincunx
Seminar Materials:
The seminar textbook is "Basic
Statistics: Tools For Continuous Improvement," by
M.J. Kiemele and S.R. Schmidt (Air Academy Press,
1991). A student version of SPC KISS statistical software is included with the
textbook. A workbook is included that contains all of the lecture material.
Who Should Attend?
Participants would include managers,
engineers, supervisors, and technicians who will be implementing or utilizing
SPC. A simplified one or two-day version of this seminar is available for
operators.
Seminar Outline:
DAY 1:
- Introduction
to Total Quality Management (TQM)
- Introduction
to Teamwork
- Why Use a Team?
- How Should the Team Work Together?
- Guidelines for Brainstorming
- Creativity - Basic
Tools for Problem Solving and Quality Improvement
- Problem Solving Methodology
- Process Flow Charts
- Cause-and-Effect Diagrams
- Problem Solving Worksheet
- Data Collection and Analysis Tools
-- SPC software demonstration/exercises
-- SPC KISS, SAS/JMP, SPC/PI+ or other client specified software to be used - Introduction
to SPC and Control Charts
- What is SPC?
- Objectives/Benefits of SPC
- History of SPC
- What is a Control Chart
- The X-bar & R (Shewhart) Chart
- "Introduction to SPC" Video
DAY 2:
- Statistical
Concepts
- Concept of Variation
- Quincunx (Bead Board) Demonstration
- The Normal Distribution
- Statistical Notation
- Properties of Distributions
- Central Limit Theorem
-- Video: Central Limit Theorem and Gambling
- Probability Distributions
- Normal Probability Plots - Overview
of Control Chart Types
- Variables
Control Charts
- Construction of X-bar & R Chart
- Interpretation and Analysis of X-bar & R Chart
-- SPC software demonstration/exercises
-- Video: SPC at a familiar factory
- Rational Subgrouping
- X-bar & S Charts
- X (Individuals) & Moving-Range Charts
- SPC software demonstration/exercises - Optional
advanced topics:
- Average Run Length (ARL) Characteristics
- Exponentially Weighted Moving Average (EWMA) Charts
- Brief Overview of Autocorrelation Problem
DAY 3:
- Attributes
Control Charts
- Definitions
- Types and Uses
- Control Limit Calculation
- Constructing a p Chart
- Sampling bowl demonstration
- Interpretation and Analysis
- Constructing np, c, and u charts - Process
Capability Studies
- Introduction to Process Capability
- Calculating Capability Indices
- SPC software demonstration/exercises
- Process Capability and Process Control
- Importance of Sample Size
- Process Capability for Non-Normal Data
- Ten Requirements for a Statistically Valid Capability Study
- Achieving Six Sigma Quality - Optional:
Acceptance Sampling
- Purpose of Acceptance Sampling
- Application of Acceptance Sampling
- Advantages/Disadvantages of Sampling
- Types of Sampling Plans
- Lot Formation
- Random Sampling
- Sampling for Attributes
- Sampling for Variables - Implementing
SPC
- Four Phase Model
- Feedback Scheme
- Flow Chart
- The SPC Team - Other
Topics
- Charts Based on Standard Values
- Short-Run SPC
- Multi-Vari Charts
- Measurement System Evaluation