SPC Training - SPC TIP

Statistical Process Control (SPC) Training and Implementation Program (SPC-TIP)

"For us, SPC-TIP is a money-saving alternative to hiring a consultant to teach our classes. We pay for SPC-TIP one time, and it teaches consistently, efficiently and effectively, each and every time. With SPC-TIP, I can sit back as a 'moderator'. SPC-TIP explains 'voice of the customer', 'voice of the process', 'spec limits vs. control limits', the 'SPC process', 'types of data' and I ask facilitating questions to help the people apply SPC-TIP's examples to their specific processes. SPC-TIP is enabling all of us at Mead to improve our use of SPC - and save training dollars at the same time."

Harvey Johnson, QA Manager
North America Packaging Division, Mead Corporation

The basis of our SPC Training:

Process stability begins with understanding that producing the highest quality at the lowest cost means constantly striving to reduce variation. In the SPC Starter Kit, instructors Anna and Dave help workers build fundamental SPC skills and understanding.

After completing the Starter Kit, operators will see the important role they play in the proper implementation of SPC. They'll be ready to work on an SPC team to rid their process of special cause variation and to avoid unnecessary adjustment.

Basic SPC training

Our basic SPC training includes the first two Course Groups. Click on a Course Group for detailed content description.

Starter Kit
Applying SPC

Advanced SPC training

Our advanced SPC training includes the following Course Groups. Click on a Course Group for detailed content description.

Process Capability Using Design of Experiments

Comprehensive SPC training

Our comprehensive SPC training includes all four Course Groups. Click on a Course Group for detailed content description.

Starter Kit
Applying SPC
Process Capability Using Design of Experiments

SPC training - Starter Kit

1 SPC and Variation

SPC's advantages vs. quality control by inspection
SPC's purpose is to "fight variation"
Differences between attribute and variables data
Explanations of special and common cause variation
How SPC can be used to detect the different types of variation in manufacturing processes

2 Pictures of Numbers - Histograms

Building, reading and identifying parts of a histogram
Histograms make visible the patterns caused by variation
Histograms can show the ability of a process to meet customer specifications

3 Introduction to Control Charts

Understanding the parts of control charts
Control charts are calculated from the process data itself
Control charts can indicate whether process variation is from common or special causes
Rules governing use and interpretation of control charts

4 Summary and Final Test for SPC Starter Kit

Summary and Final Test for SPC Starter Kit

SPC training - Applying SPC (5 courses, 6-8 hours)

Applying SPC is a natural complement to the SPC Starter Kit. In these courses, Anna and Dave make control charts a tool that operators can use with confidence for taking action, solving problems and achieving process stability.

After Course 5, the SPC team members are primed to choose and prioritize process parameters to monitor and measure and to establish a data collection plan. After Courses 6-9, operators can collect and plot data, analyze a variety of control charts, and take action when appropriate. Before going online, the team should agree on procedures to take if the charts signal an out-of-control condition.

5 Selecting Parameters

Taking a new look at your process
Preparing to collect data
Block diagrams, pareto charts, fishbone diagrams
Parameter test checklist and monitoring priorities
Manufacturing case study

6 Types of Control Charts

Control chart review -- benefits, parts, rules
Variables control charts -- X bar and R chart, X bar and S chart
Attribute control charts -- P, NP, C, U charts
Choosing the appropriate control chart

7 Setting Up and Using a Control Chart

Rules for constructing variables and attribute control charts
Calculator tutorial
Basic statistics and step-by-step directions for setting up an X bar and R Chart and a C
Chart

8 Interpretation and Action

Control chart patterns and possible causes
Control charts as an indicator of process problems
Deciding when and if to adjust a process
Steps to determine the causes of variation

9 Summary and Final Test for Applying SPC

SPC training - Process Capability (4 courses, 6-8 hours)

Because sometimes process stability is not enough to be competitive, instructors Sara and Tom inspire commitment to continuous improvement. In the following courses, they review basic SPC concepts and teach workers how to assess process capability using both variables and attribute data.

After Courses 10-13, workers will understand that more capable processes produce more product to target and less out of spec lowering costs and improving quality. Then the SPC team is ready to find out what a process is doing and prioritize processes that need improvement.

10 SPC Review

Quality is key to customer satisfaction and global competitiveness
SPC is a technique that supports continuous improvement
Reduce variation and produce as close to target as possible
Use SPC tools to help determine when to investigate and take action and when to leave a process alone

11 Introduction to Process Capability

Defined as the extent to which a stable process is able to meet specifications
Monitor process stability using control limits; assess process capability using spec limits
How dispersion changes affect a control chart and histogram
Use sample data to estimate population characteristics
Compare relative capabilities of different processes

12 Using Normal Curves

Characteristics of a normal distribution -- shape, central tendency and dispersion
Estimating standard deviation
Using the Standard Normal Table
How the area under the normal curve can predict yield and the amount of product not meeting specifications

13 Process Capability Assessment

Assessing process capability using numerical methods
Using standard deviation to calculate natural tolerance
Calculating Cp, Cpk, the differences between them and how process changes affect them
Attribute data process capability assessments using percent defective, ppm defective and ppb defective

SPC training - Using Design of Experiments (3 courses, 3-5 hours)

Processes in control may still not meet customer specifications. To help reduce common cause variation, our trainers offer a series of steps that teams can use to structure designed experiments. SPC-TIP concludes with a fun-filled case study set in ancient times where workers apply all their SPC and DOE skills to improve catapult processes.

After Courses 14-16, operators will be equipped to participate in teams planning and conducting designed experiments.

14 Introduction to DOE

Improve processes using carefully planned experiments
Expend minimal time and resources to learn as much about the process as possible
Change process or tool settings in a systematic way while a process is running to find the best combination
Key definitions and bottom line benefits of DOE

15 Application of DOE

An Approach to DOE - 5 phases
- Plan: set objectives, determine response variable, select factors, select levels for each factor, consider design constraints, consider possible interactions
- Design: use results from step 1 to set up a design matrix or map for conducting an experiment
- Run: schedule and run the experiment and accurately record data results
- Analysis: analyze data, share results and make decisions
- Act: verify results, make changes to the process, run another experiment, brainstorm other options
Fractional factorial experiment to improve popcorn yield
Manufacturing case study of an SPC team whose process is in control, but inferior to the competition's

16 An Experiment in Tirzah

Defend Tirzah, an imaginary 850 B.C. city, against invasion
Verify the stability of Tirzah's two catapult processes using attribute and variables data
Assess the capability of both processes
Use DOE to improve catapult process capability and save Tirzah!
Continue to prepare and improve catapult processes for the next invasion

For further information regarding SPC-TIP, please contact CimWorks UK at (01788) 567514