Statistical Process Control   Statistical Process Control (SPC)

(SPC)
SPC SPC Consulting SPC Training

SPC Support

SPC
– Statistical Process Control –

⇓ Introduction to SPC

⇓ What is SPC

⇓ Why Use SPC

⇓ How to Use SPC

⇓ Learn More About SPC

Introduction to SPC
Statistical Process Control (SPC) is not new to industry. In
1924, a man at Bell Laboratories developed the control
chart and the concept that a process could be in
statistical control. His name was William A. Shewart. He
eventually published a book titled “Statistical Method from
the Viewpoint of Quality Control” (1939). The SPC process
gained wide usage during World War II by the military in
the munitions and weapons facilities. The demand for
product had forced them to look for a better and more
efficient way to monitor product quality without
compromising safety. SPC filled that need. The use of
SPC techniques in America faded following the war. It
was then picked up by the Japanese manufacturing
companies where it is still used today. In the 1970s, SPC
started to gain acceptance again due to American
industry feeling pressure from high quality products
being imported from Japan. Today, SPC is a widely used
quality tool throughout many industries.

What is SPC
SPC is method of measuring and controlling quality by
monitoring the manufacturing process. Quality data is
collected in the form of product or process
measurements or readings from various machines or
instrumentation. The data is collected and used to
evaluate, monitor and control a process. SPC is an
effective method to drive continuous improvement. By
monitoring and controlling a process, we can assure that
it operates at its fullest potential. One of the most
comprehensive and valuable resources of information
regarding SPC is the manual published by the
Automotive Industry Action Group (AIAG).

Why Use SPC

Manufacturing companies today are facing ever
increasing competition. At the same time raw material
costs continue to increase. These are factors that
companies, for the most part, cannot control. Therefore
companies must concentrate on what they can control:
their processes. Companies must strive for continuous
improvement in quality, efficiency and cost reduction.
Many companies still rely only on inspection after
production to detect quality issues. The SPC process is
implemented to move a company from detection based
to prevention based quality controls. By monitoring the
performance of a process in real time the operator can
detect trends or changes in the process before they
result in non-conforming product and scrap.

How to Use SPC

Before implementing SPC or any new quality system, the
manufacturing process should be evaluated to
determine the main areas of waste. Some examples of
manufacturing process waste are rework, scrap and
excessive inspection time. It would be most beneficial to
apply the SPC tools to these areas first. During SPC, not
all dimensions are monitored due to the expense, time
and production delays that would incur. Prior to SPC
implementation the key or critical characteristics of the
design or process should be identified by a Cross
Functional Team (CFT) during a print review or Design
Failure Mode and Effects Analysis (DFMEA) exercise.
Data would then be collected and monitored on these
key or critical characteristics.

Collecting and Recording Data

SPC data is collected in the form of measurements of a
product dimension / feature or process instrumentation
readings. The data is then recorded and tracked on
various types of control charts, based on the type of data
being collected. It is important that the correct type of
chart is used gain value and obtain useful information.
The data can be in the form of continuous variable data
or attribute data. The data can also be collected and
recorded as individual values or an average of a group of
readings. Some general guidelines and examples are
listed below. This list is not all inclusive and supplied only
as a reference.

Variable data
Individual – Moving Range chart: to be used if your
data is individual values
Xbar – R chart: to be used if you are recording data in
sub-groups of 8 or less
Xbar – S chart: to be used if your sub-group size is
greater than 8

Attribute data
P chart – For recording the number of defective parts
in a group of parts
U chart – For recording the number of defects in each
part

Control Charts
One of the most widely used control charts for variable
data is the X-bar and R chart. X-bar represents the
average or “mean” value of the variable x. The X-bar
chart displays the variation in the sample means or
averages. The Range chart shows the variation within the
subgroup. The range is simply the difference between
the highest and lowest value. The following steps are
required to build an X-bar and R chart:

Designate the sample size “n”. Usually 4 or 5 are

common sample sizes used in many industries.
Remember the sample size should be 8 or less. Also
determine the frequency that the sample
measurements will be collected.
 Start collecting your initial set of samples. A general
rule is to collect 100 measurements in groups of 4
which would result in 25 data points.
Calculate the average value for each of the 25 groups
of 4 samples.
Calculate the range of each of the 25 samples of 4
measurements. The range is the difference between
the highest and lowest value in each set of 4 sample
measurements.
Calculate X-dbar (the average of the averages), which
is represented on the X- bar chart by a solid
centerline.
Calculate the average of the sample ranges or “R”
values. This will be the centerline of the Range chart.
Calculate the Upper and Lower Control Limits (UCL,
LCL) for each chart. To be clear, the control limits are
not the spec limits set by the engineer on the
drawing. The control limits are derived from the data.
Most engineers utilize statistical software that will
perform the calculations automatically.

Once the chart is setup, the operator or technician will

measure multiple samples, add the values together then
calculate the average. This value is then recorded on a
control chart or X-bar chart. The range of the subgroups
is also recorded. The sample measurements should be
taken and recorded in regular intervals, including date
and time to track the stability of the process. Watch for
any special or assignable causes and adjust the process
as necessary to maintain a stable and in control process.
The X-bar and R chart is merely one example of the
different control charts available for process monitoring
and improvement. For assistance in determining the best
practices to improve your processes, contact one of the
many professionals at Quality-One.
Analyzing the Data
The data points recorded on a control chart should fall
between the control limits, provided that only common
causes and no special causes have been identified.
Common causes will fall between the control limits
whereas special causes are generally outliers or are
outside of the control limits. For a process to be deemed
in statistical control there should be no special causes in
any of the charts. A process in control will have no
special causes identified in it and the data should fall
between the control limits. Some examples of common
cause variation are as follows:

Variation in material properties within specification

Seasonal changes in ambient temperature or
humidity
Normal machine or tooling wear
Variability in operator controlled settings
Normal measurement variation

Adversely, special causes generally fall outside of the

control limits or indicate a drastic change or shift in the
process. Some examples of special cause variation are
below:

Failed controllers
Improper equipment adjustments
A change in the measurement system
A process shift
Machine malfunction
Raw material properties out of design specifications
Broken tool, punch, bit, etc.
Inexperienced operator not familiar with process

When monitoring a process through SPC charts the

inspector will verify that all data points are within control
limits and watch for trends or sudden changes in the
process. If any special causes of variation are identified,
appropriate action should be taken to determine the
cause and implement corrective actions to return the
process to a state of statistical control.
There are other variations or patterns of data points
within the control limits that should also be tracked and
investigated. These include but are not limited to:

Runs where 7 or more data points are in a row on

one side of the process centerline
Changes in the normal spread of data, where
multiple data points fall either farther apart or closer
together
Trends which are represented by 7 or more data
points consistently raising or declining
Shifts in the data spread above or below the normal
mean

By addressing any special causes, trends or shifts in the

process we can assure we are producing parts that meet
the customer’s requirements. Remember the control
limits should always fall between the spec limits
determined by the engineer and / or the customer. For
more information regarding the SPC process and
available tools, mentoring, training or assistance in
implementation of SPC, contact one of the Subject
Matter Experts (SME) at Quality-One. We are always
ready to provide any assistance or information you made
need.


SPC - Control Charts

Learn More About SPC

Quality-One offers Quality and Reliability Support for
Product and Process Development through Consulting,
Training and Project Support. Quality-One provides
Knowledge, Guidance and Direction in Quality and
Reliability activities, tailored to your unique wants, needs
and desires. Let us help you Discover the Value of SPC
Consulting, SPC Training or SPC Project Support.