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.

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

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.

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.

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