Gain control of your processes through Statistical Process Control (SPC)

Download as PDF

The module in a nutshell

Wouldn’t it make life a lot easier if our processes performed reliably? If they consistently delivered what they were supposed to – time after time, day after day? Unfortunately for most businesses they don’t. The result is defects, delays, extra costs, dissatisfied customers. Variation can kill businesses.

All processes suffer from variation. Variation in process inputs – raw materials, equipment, process users, etc - ultimately causes variation in process performance. The way something varies can expose the cause of problems and point towards an appropriate solution. On closer inspection process variation takes two forms. All processes have inherent natural variation that over time assumes a consistent and predictable pattern. Although we cannot predict what will happen from hour to hour, day to day, over time natural or common cause variation develops a pattern that is in itself predictable.

What makes process management difficult is the presence of unnatural or special cause variation. It’s these special causes impacting our processes that result in the sudden departure in performance from the natural expected and predictable process variation. A process containing special causes is unpredictable and out of control. We do not know when they will occur, we do not know the magnitude of the impact they will have on our performance.

Statistical process control (SPC) utilizes control charts that graphically monitor process and product parameters statistically over time. This allows us to identify when those special causes occur. It provides us with the signal that we need to take action to regain control of the process. Coupled with a methodical problem solving process, organisations can make great advances in performance by rooting out and eliminating these special causes, transforming unstable, unpredictable processes into those that are consistent and repeatable.

Through a long heritage of application in many diverse industries, SPC has demonstrated its use as a technique for:

maintaining control of critical process inputs thereby preventing problems downstream 
reducing unnecessary process adjustments that can paradoxically cause more problems if allowed to continue 
providing useful diagnostic information in problem investigation 
providing information about process performance and capability.

The aim and outcomes of the module

The aim of this SPC workshop is to provide you with the skills required to:

1. construct control charts for the control of critical product or process parameters 
2. be able to use control charts on an ongoing basis to identify when special causes impact the process 
3. instruct process users in the use of control charts within their processes.

After successfully completing the workshop participants will be able to:

• Describe the difference between common and special cause variation in a process 
• Understand the difference between Attribute data and Variable data 
• Select the appropriate control chart for a given application 
• Perform control limit calculations by hand and with the use of Minitab 
• Identify any ongoing actions required to maintain control chart performance

Who Gain control of your processes through Statistical Process Control is for

This module is suitable for any organisation that needs to gain control of their processes. It is aimed at process improvement personnel but would also be very well suited for process owners who are challenged with improving performance.

What’s in Gain control of your processes through Statistical Process Control

This SPC workshop follows a balanced mixture of theory and practical application. Delegates will learn about:

• The nature of process variation and the impact of common and special causes of variation 
• Measuring process performance – process capability metrics 
• The application of SPC for process control and process improvement 
• How to construct and use the variable data control charts 
  • Individual and Moving Range charts (I-MR)
  • Mean and range charts (X-Bar R) 
• How to construct and use the attribute data control charts
  • p and np charts
  • c and u charts

Important other information

Duration: Gain control of your processes through Statistical Process Control lasts for one day and can be used by itself or in combination with other modules in the Process Transformation Programme.

Location: Ideally a room close to the workplace of participants, though it can be run off-site effectively.

In common with other modules in the Process Transformation Programme the module is designed to run successfully with between 8 to 18 participants.

Price: As a stand-alone module, £2,500 inclusive of all materials. This price does not include expenses which are charged at cost..

Contact for more information:

Karen Dunn
Burge Hughes Walsh
Suite 13b
Castle Mound Way
Central Park
Rugby CV23 0UZ

Telephone: 01788 550015
email: kdunn@burgehugheswalsh.co.uk