TM

Inspiring Minds

Starting from 01st September 2020

Advanced Statistical Process Control
18 hrs. of Online Program
Faculty: Mr. Mahesh Hegde

Who need this skills ?

• Quality heads, mangers,
engineers
• Production managers,
engineers
• Design and
development heads,
managers, engineers
• Business excellence Basics to Advanced level Unique Contents
heads, managers, MRs Refer next page
internal auditors

2 Goals of SPC

1. Goal of SPC is to achieve consistent results from process with predictable

outcomes. It means process is free from abnormality. Such Process is called “Stable
Process” or “ Process is in Statistical control”.
For example - Quantity of cool drink in a bottle, Mileage of a car, Time to deliver
pizza are important to respective customers and customers don’t like variations. So
it is important to achieve consistent results. To attain state of stable process, it is
important to find abnormalities one by one, find its causes and take corrective
action to avoid recurrence. Control charts gives indication that there is some
abnormality in process and helps process owner to quickly understand that there is
some change.

2. Another goal of SPC is to reduce the variation smaller than allowed variation. In
other words variation is smaller than specification limits or also called “capable
process”
Advanced SPC Contents
• 1. SPC Introduction: Points before SPC, Why SPC is needed?, Taguchi Loss Function Curve, Product control Vs. Process
control. Common and Special cause, Type 1 and Type 2 errors.
• 2. SPC for daily management : 2x2 Matrix, Common and special cause strategy, Actions based on 4 situations, how to
take CA in case of abnormality?
• 3. Basic Statistics :Standard Deviation, How to interpret Standard Deviation?, Method to apply day to day.
• 4. Normal Distribution: How to make histogram in excel, Stratified histograms, Histogram interpretations, Applications.
Normality Test,
• 5. PPM Prediction and Ppk, Sigma Level Calculations : Calculation of Z, area under the curve using excel sheet and
predicting PPM from development data. Exercises and practical Examples. Z Bench mark, Sigma Level calculation for
Variable and Attribute data.
• 6. Basic Control Charts for variable data: Need for charting the data. Advantages of control charts. Control Chart
Principles: Control limits and specification limits. Steps in implementation of control charts. Selection of appropriate
control chart.
• IMR chart :Prerequisite for IMR chart, Method of plotting in excel, Rules for interpretations. Examples, Advantages and
limitations.
• Subgroups : 5 principles of subgroup, Rational Subgroup, discussions on subgroup, Advantages of rational subgroup
• X- Bar R chart: Within subgroup and between subgroup variations. Method to collect the data and establish the control
limits. Monitoring of process. Steps before recalculating control limits. Practical usage. Advantages and limitation. Practical
exercises. Discussions
• X bar & S chart, Median Range chart - Application, formula advantages and limitations.
• Misconceptions on control charts. Discussions
• 6. Process Capability and Process performance: Need for using indices. Steps before calculating Pp, Ppk. Method to
calculate Pp, Ppk - interpretations and actions. Cp, Cpk Calculations, interpretations and various actions based on the
study. Comparison of both the indices. Indices for unilateral tolerances. Machine capability study. Method to conduct,
calculate and interpretations. Conversion of PPM to Ppk. Usage of Cpm. Effect of sample size on Ppk studies. Methods
to establish the CI for Pp, Ppk and Cp, Cpk. CR and PR
• 7. Attribute control charts: Selection of control charts. Discussion on application of these charts. P, nP, C & U charts.
Method to establish the sample size for attribute charting. Control limit calculations and interpretations. Practical
exercise on attribute control chart. Advantages and limitations.
• 8. Additional Control Charts and advanced control charts:
• Pre control chart: Method to collect data. Advantages and limitations. Exercises to calculate limits in case of 2 sided
tolerance, zero the better and higher the better.
• Stop light control chart : Scope for practical application, Method to collect the data, analysis and actions. Advantages and
limitations. Exercises. Discussions on application
• Short Run SPC: Need, advantages DNOM Chart -Application, Assumptions to be made, Method to collect data, Control limits,
Interpretations and discussions on applications
• CUSUM Chart and EWMA charts : Application, exercise using Minitab EWMA Chart
• 9. Control Chart for special practical applications: Additional Discussions on special situations: Slowly drifting process
(tool wear), Control chart for fast drifting process (Set up limits), Control chart for set up dominant process (upper and
lower setup limits), Data from multiple streams.
• 10. Capability Analysis for Non normal data: Reasons for non normality, Initial steps, Distribution Search, Box Cox and
Johnson Transformations, Exercises on transformations. Control Charts for non normal data, Pppk for non normal data,
Percentile method for non normal data

TM

Inspiring Minds
WHY DO WE NEED CONTROL CHART
• All products and services are outcome of a process. There are important
parameters in the product or service which affects the customer or our business.
We find variation in these parameters. For example time to deliver Pizza, weight
of a product, quantity of cool drink in a bottle, time to process invoice, mileage of
a vehicle have variation. All these parameters are outcome of a process which
results into variation.
• Questions which SPC can answer to make further decision by
management
1. Whether process is stable? Whether process is having only common cause
variation or whether process has assignable causes? Whether the outcome of
the process is predictable?
2. Whether we need shift the mean, reduce variation or current mean and
variation is acceptable?
3. To minimize variation whether we need to work on structured approach /
investment on better process or whether we need to take corrective actions
one by one on abnormality?

• Such kind of clear understanding of process can happen by measuring the

outcome of the process at defined period systematically and analysing them
using control chart and process capability. This helps to make several decisions
like whether management needs investment or structured problem solving for
the same or whether variation can be reduced just by working on special causes.
Such decisions can be taken by implementing SPC. Organization can work on
making more and more parameters stable and capable. This helps to reduce
variation, improve quality, reduced inspection, reduced COPQ.
TM

Inspiring Minds
 COURSE
Uniqueness Duration & Details

• Faculty with in-depth knowledge and

expertise on the subjectswith • 18 hrs. of online training
implementation experience for • 2.30 hrs. on 1st Sept 2020 from 07.00 PM to
various processes 09.30 PM
• 2.30 hrs. on 2nd Sept 2020 from 07.00 PM to
• Extenstive course content – 09.30 PM
application oriented topics • 4 hrs. on 6th Sept 2020 from 09.00 PM to 01.00
PM
• Individual exercises • 2.30 hrs. on 8th Sept 2020 from 07.00 PM to
09.30 PM
• Videos to explain concept further • 2:30 Hours on 9th Sept 2020 from 07.00 PM to
9:30 PM
• Examples from industry
• 4 hrs. on 13th Sep 2020 from 09.00 AM to 01.00
PM
• Usage of MS Excel
Fees
• Rs.5000/- + 18% GST per participant.(Total Rs.5900/-) in advance

• Rs.4500/-+ 18% GST per participant if there are more than 3 participant

• Payment détails Need to be intimated to Deval Yawalkar

([email protected] or +91 9765774651)

Account Details
Beneficiary Name: Mahesh Hegde Type of Account: Current Account
Name of the Bank: ICICI Bank Bank Account No.: 108805000100
RTGS/NEFT IFSC Code: ICIC0001088 Branch: Mahatmanagar , Nashik

For Registration contact:

Mr. Deval Yawalkar
[email protected]
TM
+91 9765774651
Inspiring Minds
The Faculty
Mahesh Hegde is a passionate trainer and TQM counsellor.
He is training and handholding large as well as medium Mr. Mahesh Hegde
sized organizations in India and overseas in their “Journey
of Excellence.” He is working as an independent TQM
counsellor since 2010 and formed LearnEx Consulting
Mahesh has trained more than 10,000 people, including serval 100s of Six
Sigma Black belts, he has facilitated more than 2000 projects in 16 years of
consulting which has helped organizations to get significant benefits in quality,
cost and won various prestigious awards. His structured approach of problem
solving is unique by taking best from QC story, 6 Sigma, Shainin & 8D methods.

Mahesh has trained top leaders of organizations on TQM practices. His

structured way of “Daily Management, Dexterity, FMEAs, SOPs” have been
implemented in companies in India and overseas. He has integrated number of
proactive tools for achieving “First time Right” and developed unique way of
preparing process FMEAs. It include human error prevention techniques of
Dr.Nakjo, Past Trouble Data base, Master Ishikawa, Cause analysis table etc.
With his team of consultants, he has successfully guided implementing
thousands of actions proactively.

Mahesh was leading flagship program “Post Graduate Diploma in Quality

Management” Of Mahindra Institute of Quality and got learning from eminent
faculty members including Dr.Kume, Dr.Washio, Dr.Nakajo, Mr.N.Ramanathan.
He is trained by “Renault Nissan Institute” of France on System Production
Renault (SPR). As a lead auditor for ISO/TS16949 and consultant, he has
facilitated 15 companies to implement QMS during 2004 to 2006. Prior to that
Mahesh was part of Quality Assurance and leading QMS journey in auto
industry.

Mahesh is been key speaker in various quality forum and has presented
number of technical papers at various places including in International
Conference in Quality - Japan, Asian Network of Quality, Alucast. His strength
includes depth in the subject, practical application and impactful training
delivery along with magic.