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Statistical Process Control

Statistical Process Control (SPC) is a methodology used to monitor and control manufacturing processes. SPC uses statistical charts to determine if a process is in or out of control and to identify causes of variation that require corrective action. Key aspects of SPC include using control charts to monitor processes, investigating out-of-control signals to determine assignable causes, and making process adjustments to reduce variation and improve quality. SPC tools like Pareto charts, cause-and-effect diagrams, flow charts, and check sheets help identify, prioritize, and gather data on quality problems to aid process improvement.

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242 views

Statistical Process Control

Statistical Process Control (SPC) is a methodology used to monitor and control manufacturing processes. SPC uses statistical charts to determine if a process is in or out of control and to identify causes of variation that require corrective action. Key aspects of SPC include using control charts to monitor processes, investigating out-of-control signals to determine assignable causes, and making process adjustments to reduce variation and improve quality. SPC tools like Pareto charts, cause-and-effect diagrams, flow charts, and check sheets help identify, prioritize, and gather data on quality problems to aid process improvement.

Uploaded by

nikki
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Statistical

Process
Control

Statistical Process Control is an


analytical decision making tool
which allows you to see when a
process is working correctly and
when it is not. SPC is also a
methodology for monitoring a
process to identify special causes of
variation and signaling the need to
take corrective action when it is
appropriate.

Brief History
The foundation for Statistical
Process Control was laid by Dr.
Walter Shewart working in the Bell
Telephone Laboratories in the
1920s conducting research on
methods to improve quality and
lower costs. He developed the
concept of control with regard to
variation, and came up with
Statistical Process Control Charts
which provide a simple way to

What exactly are


process control
charts?
Control
charts show
the variation
in a
measurement
during the
time period
that
the process is

What exactly are


process control
charts?
Process
control
charts are
fairly
simplelooking
connected
-point
charts.

Purpose of SPC
Control

charts are an essential


tool of continuous quality control.
Monitor processes to show how
the process is performing.
How the process and capabilities
are affected by changes to the
process.
Used to determine the capability
of the process

Purpose of SPC
It

can help identify special or


assignable causes for factors
that impede peak performance.

This all information is


then used to make
quality
improvements.

How do SPC works?


Control charts show if a process is
in control or out of control. They
show the variance of the output of a
process over time, such as a
measurement of width, length or
temperature. Control charts compare
this variance against upper and
lower limits to see if it fits within the
expected, specific, predictable and
normal variation levels.

In control? Out of control?


Whats the point?
If a process is in control, the
outcomes of the process can
be accurately predicted.
If a process is out of control,
the next step is to look for the
assignable causes for the
process output, to look for the
out-of-controlness.

In control? Out of control?


Whats the point?
If this out-of-controlness is
considered negative, such as
multiple defects per part, the
reasons for it are investigated
and attempts are made to
eliminate it. The process is
continuously analyzed to see if
the changes work to get the
process back in control.

Steps Involved In Using


Statistical Process
Control

Proper Statistical Process


Control starts with planning
and data collection. Statistical
analysis on the wrong or
incorrect data is rubbish, the
analysis must be appropriate
for the data collected.

Steps Involved In Using


Statistical Process
Control
Be sure to PLAN, then

constantly re-evaluate your


situation to make sure the plan
is correct.
The key to any process
improvement program is the
PDSA cycle described by
Walter Shewart.

Steps Involved In Using


Statistical Process
Control

Steps Involved In Using


Statistical Process
Control
Plan
Identify the problem and the
possible causes. The QC tools
described in this manual can
help organizations identify
problems and possible
causes, and to prioritize
corrective actions.

Steps Involved In Using


Statistical Process
Control
Make
changes
designed to
correct or
improve the
situation.

Do

Steps Involved In Using


Statistical Process
Control
Study the effect of these
changes on the situation. This
is where control charts are
used they show the effects
of changes on a process over
time. Evaluate the results and
then replicate the change or
abandon it and
Stutry something
different.
dy

Steps Involved In Using


Statistical Process
Control
If the result is

Act

successful,
standardize the
changes and then
work on further
improvements or the
next prioritized
problem. If the
outcome is not yet
successful, look for

Steps Involved In Using


Statistical Process
Control

Steps Involved In Using


Statistical Process
Control

Quality
Control
Measureme
nt

Two Categories
Attribute
Qualitative data that can
be counted for recording
and analysis. Examples
include:
Number of defects,
number of errors in a
document; number of
rejected items in a sample,

Two Categories
Variable
Data values which are
measurements of some
quality or characteristic of
the process. The data
values are used to
construct the control
charts.

Specific SPC Tools


Pareto Chart
Cause-and-Effect Chart
Flow Chart
Scatter Diagram
Check Sheet
Probability Plot
Histogram

Identification & Data


Gathering
When you set out to
improve quality, the first
thing to do is identify the
processes that need
improvement. This can
be done using a number
of methods such as
surveys, focus groups or
simply asking clients

Prioritizing
After a number of
possible problems are
noted, the next step is
to prioritize. The
problems that are
having the greatest
effect are the highest
priority items.

1. Pareto Chart

Pareto chart
is a vertical
bar graph
displaying
rank in
descending
order of
importance for
the categories
of problems,
This is a Pareto chart
of or
defects
complaints from a customer
opportunities.

2. Cause-and-Effect Chart
The
fishbone chart
organizes and
displays the
relationships
between
different
causes for
the
effect
that
The method for using this chart is
is being
to put the problem to be solved.
examined.

2. Cause-and-Effect Chart
The
fishbone chart
organizes and
displays the
relationships
between
different
causes for
the
effect
that
This chart helps organize the
is being
brainstorming process.
examined.

3. Flow Chart

After a
process has
been
identified for
improvement
and given
high priority,
it should then
be broken
down into
specific steps
and put on

3. Flow Chart

Flowcharts
use a set of
standard
symbols to
represent
different
actions:
Circle / Oval
Beginning or
end
Square
A process,
something

4. Scatter Diagram
The Scatter plot
is another problem
analysis tool.
Scatter plot is
used to uncover
possible cause-andeffect relationships.
In this example, there appears to be a
relationship between height and weight.
As the student gets taller, generally

5. Check Sheet
Check sheets are simply
charts for gathering data.
When check sheets are
designed clearly and
cleanly, they assist in
gathering accurate and
pertinent data, and allow the
data to be easily read and
used. The design should
make use of input from

6. Histogram

Now you
can put the
data from the
check sheets
into
Aa
histogram
histogram.
is a

snapshot of
the variation of
a product or
It often forms the
bellshaped curve which the results of a
process.
is characteristic of a

6. Histogram
A histogram can show
characteristics of the process
being measured, such as:
Do the results show a normal
distribution, a bell curve? If not,
why not?
Does the range of the data
indicate that the process is
capable of producing what is
required by the customer or the
specifications?

6. Histogram
A histogram can show
characteristics of the process
being measured, such as:
How much improvement is
necessary to meet
specifications? Is this level of
improvement possible in the
current process?

7. Probability Plot
The
probability plot
is a graph of
the cumulative
relative
frequencies of
the data,
plotted on a
If the data is normal
it
normal
forms a line that is
fairly
probability
straight.
scale.

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