THE USE OF NON-STATISTICALLY

BASED PROCESS CONTROL

METHODS
Tools & Tips Webinar sponsored by the
AESQ Process Control Methods SMIG
March 8, 2023
AESQ – Aerospace Engine Supplier Quality Strategy Group
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Non-Statistical Methods
Agenda – 60 minutes
Overview – P. Teti

Who is the PCM Subject Matter Interest Group – P. Teti

Why this webinar? Where can we find help?

Paul Gorg Pete Teti
PCM Community of Practice – Linked In Engineering Manager - Aluminum Fellow, Quality Engineering
Operations Pratt and Whitney
PCC Structurals
Non-Statistical Methods Walk Through – Paul Gorg

Case Studies – Paul Gorg

Q&A – PCM SMIG Team

Summary and Close – P. Teti

AESQ – Aerospace Engine Supplier Quality Strategy Group 2

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WEBINAR OVERVIEW
We are recording today’s webinar and
will distribute the video link following the
close of the webinar. It will also be
posted on the AESQ website for free
viewing.

We will take questions during today’s

webinar using the Chat feature.

Please remain on Mute during the

presentation to prevent background
noise. We will also be muting all lines at
the start of the session.

AESQ – Aerospace Engine Supplier Quality Strategy Group 3

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The use of non-statistically based process control method
Why this webinar?

Identify non-statistical methods and when they can

be used. Discuss advantages and disadvantages.
Show practical applications and examples of
common methods. Generate thought about using
alternate methods.
Promote the available free documents and tools that
can be used by any AESQ supplier
Answer questions suppliers may have about non-
statistical based process oontrol methods.
AESQ – Aerospace Engine Supplier Quality Strategy Group 4
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PROCESS CONTROL METHODS PER RM13006
Purpose of this reference manual

RM13006 provides the user with an array of practical approaches to

process control used to ensure consistent product quality.

The purpose of this reference manual is to raise the overall capability of

the aerospace engine supply chain, standardize the process control
requirements across AESQ suppliers, and build on the requirements for
process control methods (ref. RM13006).

This reference manual was developed by a dedicated team from AESQ

member companies with expert knowledge and experience in the areas
of process control, process improvement, quality systems, and supplier
engagement.

AESQ – Aerospace Engine Supplier Quality Strategy Group 5

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PROCESS CONTROL METHODS SUPPORT
What is the Process Control Methods SMIG Group?
• The purpose of the PCM Subject Matter Interest
Group is to promote the effective deployment of the
process control methods across the AESQ Supply
Chain.
• The Group is made up of Subject Matter Experts
from the AESQ Member Companies.
• The Group is accountable for the AS13100 related
Requirements and associated Reference Manual
content, ensuring that it is up to date and reflects
current knowledge and best practice.
NO. FUTURE WEBINAR TOPICS TARGET DATE/TIME
• It shall promote the effective deployment of the 1
Process Control Methods - What is RM13006?
Interaction with other AESQ Reference Manuals 12/6/2022 (completed)
Reference Manual using Communities of Practice 2 What makes a good Process Capability Study? 1/26/2023 (completed)

(CoP). The CoP is open to any subject matter expert 3

4
Process Capability Study for True Position (handling MMC)
The use of non-statistically based process control methods
2/8/2023 (completed)
3/8/2023 (completed)

or individual experienced or trained in process 5 The Power of Precontrol 4/11/2023 (11 AM U.S. Eastern)

control from the aero engine community. 6

7
The One-Hour Process Control Assessment
Why is statistical control a prerequisite for process capability?
5/16/2023 (11 AM U.S. Eastern)
Target 2nd Qtr (June)
8 Dealing with Non-Normal Data Target 3rd Qtr (September)
• Activities may include webinars, best practice 9 Conducting capability studies for one-sided geometric tolerances Target 4th Qtr (October)
Go to https://aesq.sae-itc.com/events for webinar schedule
sharing, development of shared training materials,
conferences and published papers. https://aesq.sae-itc.com/interest-groups

AESQ – Aerospace Engine Supplier Quality Strategy Group 6

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SUBJECT MATTER INTEREST GROUPS
Who is the Process Control Methods SMIG Team?

Pete Teti
Andrew
Stout Nicklas Curator for RM13006
Paul Gorg
PWA Godebu
PWC PCC
(Leader) GKN
(Co-Lead)
Experts who you may
address process control
related question to
Rudi Karen Steve
Ricardo
Braunrieder Scavotto Hampton
Banuelas
MTU PWA PCC
Rolls Royce Provider of process
control related webinars.
See Slide 6 for webinar
Grant Geoffrey Marnie Shailesh schedule which is subject
Braun Carpentier Ham Shinde
PCC Safran GE RR to change based on your
feedback
AESQ – Aerospace Engine Supplier Quality Strategy Group
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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
PROCESS CONTROL METHODS CoP
Where to get help

AESQ Supplementary Materials webpage for a

copy of RM13006 and supporting templates
https://aesq.sae-itc.com/supplemental-material

Subject Matter Interest Group – meets monthly –

supports continuous improvement of RM13006 and
supporting templates & tools
AESQ Process Control Methods Community of
Practice (CoP) on Linked-In
Current membership is 175 – let’s get some more!!
https://www.linkedin.com/groups/12647920/

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 A WALK THROUGH OF NON-STATISTICAL
PROCESS CONTROL METHODS MATERIAL IN
RM13006
SECTIONS INVOLVING PROCESS CAPABILITIES IN RM13006

• TABLE 1 OVERVIEW OF RECOGNIZED PROCESS CONTROL METHODS

• 5.1 ERROR / MISTAKE PROOFING
• 5.4 RUN CHARTS WITH NON-STATISTICAL LIMITS
• 5.6 LIFE / USAGE CONTROL
• 5.8 VISUAL PROCESS CHECK AND CHECKLIST
• 5.9 FIRST PIECE CHECK
• 5.10 TEST PIECE EVALUATION FOR PROCESS CAPABILITY

AESQ – Aerospace Engine Supplier Quality Strategy Group 9

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WHAT IS PROCESS CONTROL?
The overall strategy employed to reduce and mitigate product & process risks resulting in the full achievement
of Customer requirements.

Process Control includes the use of statistical and non-statistical methods that work to prevent and detect
errors such that defects/defective parts are not created in the first place.

Statistical techniques include such tools as control charts for variable & attribute data

Non-statistical techniques include the use of mistake-proofing devices to control process inputs. Such
devices may take the form of asymmetrical fixture designs, one-way fits, alarms, buzzers, work instructions,
procedures, checklists, and set-up qualification & lot monitoring using PreControl to name a few.

Control Chart: Blade length

1.266
UPPER CONTROL LIMIT The maximum value
1.262 UCL expected to be seen
Measured Value of a Key

1.258
Characteristic

1.254
CENTER LINE The average value
1.250 CL expected to be seen
1.246

1.242
The minimum value
1.238 LCL expected to be seen
LOWER CONTROL LIMIT
1.234
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
LSL Target USL

One-Way Fit
Time Order

Statistical and…………..Non-Statistical Methods together drive reduction and control of variation

AESQ – Aerospace Engine Supplier Quality Strategy Group 10
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THE USE OF NON-STATISTICALLY BASED PROCESS
CONTROL METHODS
Highlights Prevention Control
One-Way Fits
Why non-statistical methods
When to use non-statistical
methods
Methods and examples
“240 solutions; every ME
and QE should have”
www.productivitypress.com

Prevent the cause of the failure mode

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WHY USE NON-STATISTICAL PROCESS
CONTROL METHODS
When to use and advantages
• Process can be Error or Mistake proofed. Elimination of defect is possible.
• If process data does not easily lend itself to statistical methods
• Easier for operators to understand and accomplish
- Can be done on shop floor

- Immediate feedback, waiting for data analysis not required

• Cost, may be less expensive to organization.

AESQ – Aerospace Engine Supplier Quality Strategy Group 12

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WHY USE NON-STATISTICAL PROCESS CONTROL
METHODS
When not to use and dis-advantages
• Process data lend itself to statistical analysis and is easily collected.
• Process capability metrics are needed to meet customer or
organizational requirements.
• Data is needed forr process development / improvement.

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NON-STATISTICAL METHODS
Error / Mistake Proofing
Control Plan to RM 13004

HIGH RISK
A key goal of Process Control is to help mitigate risks.
Non-statistical methods such as Mistake-Proofing is Mistake Proofing
applied for the highest risks identified on a PFMEA.

SPC
Definition:
Using wisdom and ingenuity to provide Inspection and Target Setting
methods and devices that allow you to
do your job
Audit
100% defect free - 100% of the time
LOW RISK

Manufacturing Controls

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NON-STATISTICAL METHODS
Error / Mistake Proofing
Linkage to RM13010 – Human Factors

Human Error
• Humans make mistakes (errors) because of……
• Forgetfulness' / misunderstanding requirements
• Lack of experience/skills – Lack of concentration
• Lack of standards
• Rushing – Taking short cuts
• Malicious intent (deliberate action; this is rare)
• Errors that lead to defects

• Defects are not inevitable and can be eliminated by use of simple, low cost methods to achieve
zero defects

• Mistake proofing should take over repetitive tasks that depend on vigilance or memory.
AESQ – Aerospace Engine Supplier Quality Strategy Group 15
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NON-STATISTICAL METHODS
Error / Mistake Proofing

Mistake Proofing History

• Dr. Shigeo Shingo attributed with developing methods
• Originally called idiot proofing but recognized this label could offend
workers so changed to mistake proofing (Poka-Yoke in Japanese.
• Literally translated
• Yokeru: To avoid
• Poka: Inadvertent errors
• Target of zero defects and elimination of QC inspection

AESQ – Aerospace Engine Supplier Quality Strategy Group 16

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NON-STATISTICAL METHODS
Mistake Proofing Most Common Errors
• Incapable or improper • Leaving out a part
measurement system employed
• Misunderstanding
• Skipping a process step or tasks
requirements
• Performing process steps
• Adjustment mistakes
incorrectly or in the wrong order
• Timing mistakes
• Using the wrong part or tool
• Contamination

AESQ – Aerospace Engine Supplier Quality Strategy Group 17

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NON-STATISTICAL METHODS
10 key sources of defects

1. Omitted processing 6. Processing wrong workpiece

2. Processing errors 7. Wrong operation performed

3. Errors setting up workpiece 8. Adjustment error

4. Missing parts 9. Equipment not set up properly

5. Wrong parts 10.Tools & jigs improperly prepared

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NON-STATISTICAL METHODS
Error/ Mistake-Proofing

Error proofing devices can take four forms. The hierarchy (1. being the
best) of these is:
1. Elimination – design the product or process hardware/software in such a way
that an error is not possible.
2. Control – prevent an error being made by detecting it before it has an effect.
3. Signal – provide an immediate and obvious warning to prevent or highlight an
error.
4. Facilitation – methods of guidance that make error less likely or will catch it.

AESQ – Aerospace Engine Supplier Quality Strategy Group 19

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NON-STATISTICAL METHODS
Levels of Error/ Mistake-Proofing

Level 1
One-Way Fit

Control Chart: Blade length

1.266
UPPER CONTROL LIMIT The maximum value
1.262 UCL expected to be seen

Measured Value of a Key

1.258

Characteristic
1.254
CENTER LINE The average value
1.250 CL expected to be seen
1.246

1.242
The minimum value
1.238 LCL expected to be seen
LOWER CONTROL LIMIT
1.234
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Time Order

Level 2
Warning Device

Level 3
Overcome existing hazard

AESQ – Aerospace Engine Supplier Quality Strategy Group 20

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NON-STATISTICAL METHODS
Levels of Error/ Mistake-Proofing

LEVEL I

Mistake cannot
be made

No need to
inspect that oil fill
tube is installed
in wrong port

Defect is not
possible since
mistake is not
possible

AESQ – Aerospace Engine Supplier Quality Strategy Group 21

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NON-STATISTICAL METHODS
Levels of Error/ Mistake-Proofing

LEVEL II

Mistake has
been made

Mistake is caught
by the control
(the fixture)

Mistake can be
fixed before a
defect is made

AESQ – Aerospace Engine Supplier Quality Strategy Group 22

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NON-STATISTICAL METHODS
Levels of Error/ Mistake-Proofing

LEVEL III

Mistake has
been made

Defect is caught
by the control
(the jig)

Defect is
contained

AESQ – Aerospace Engine Supplier Quality Strategy Group 23

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NON-STATISTICAL METHODS
More Mistake-Proofing Examples

• Guide Pins used to assure a one-way fit of a tool, • Use of machine probing as either a control during
fixture or part to prevent incorrect orientation. manufacturing to check a size before final cut or as a
signal after final cut to detect an anomaly or identify
• An alarm used to alert an operator that a machine that an adjustment may be needed.
cycle has been attempted with a misaligned tool. The
operator can take action to correct the • Asymmetrical design of a nameplate that assures it is
installed in only one possible orientation preventing
• A limit switch used to detect correct placement of a backwards or upside-down installation.
work piece.
• A left/right two button hand operated system with foot
• Counters can be used to help an operator track the switch operation to ensure hands are free prior to
correct number of components needed in an cycling a press.
assembly.
• Automated weighing of a part or batch to ensure part
• A checklist used to assure all key steps are completed is completely processed or batch is complete and
by the operator to prevent missing something that present before moving to the next operation.
could cause an escape and/or defect.

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NON-STATISTICAL METHODS
Non-Statistical Control Charts

Example Run Chart Example Pre-Control Chart

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NON-STATISTICAL METHODS
Non-Statistical Control Charts

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NON-STATISTICAL METHODS
Life / usage control
Processes may have factors that are dynamic in nature and change through use or over time. Such processes may
require control methods that prevent the process (or its factors) reaching a condition that will adversely affect the
product of the process. Such controls can be placed on, e.g. chemicals, wearable items such as cutting tools, and
other consumables.

The control criteria for life/usage controls may be defined in many ways.

For example:
1. Age
2. Number of parts processed
3. Total running time, number of cycles
4. Once opened use by date
5. Weight of parts processed and surface area processed.

The life/usage limits should ideally be determined to maximize the process quality. Statistical studies and experiments
will allow the life to be optimized for other factors such as cost. These studies may be performed on test pieces and
scaled to the production process. The life/usage limits should be validated however usually at process qualification

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NON-STATISTICAL METHODS
Life / usage control
Examples of control application include:

• A cutting tool has a maximum operating time. The tool life is recorded on a machine-readable chip. The machine
program includes code that checks the life of the tool prior to use. When cutting tips are replaced and the tool is set
a pre-setting operation resets the readable chip to zero.

• A peening operation has media that is controlled based on the total equipment running time. A timer is installed on
the equipment to indicate how close the process is to a media change. In addition to this method of control, the
process also has assessment for media quality and uses test pieces to qualify the process for correct operation.

• The concentration of a chemical etch bath is routinely maintained with an auto-dosing system. However once a
month the entire system is emptied, cleaned out, and refilled. To keep the planning of this control simple this is done
at a defined time regardless of use – for example the morning of the first Monday in every month.

• A life/usage limit may also incorporate a check and reset. For example, a wearable item may be tested after a
number of cycles and found to have not reached a point where change is required. The tool may be returned for
use for a defined number of cycles. It should be noted that this does not imply the tool will be run to the point of
failure.

AESQ – Aerospace Engine Supplier Quality Strategy Group 28

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NON-STATISTICAL METHODS
Visual process check and checklist
For characteristics that are not easily measured or are appearance in nature a
visual process check or checklist may be appropriate. Checklist and visual
standards can be developed to assist in the inspection. A single person check may
have some inherent risks of error. To increase robustness, a “double scrutiny”,
and/or “buddy check” may involve two personnel to positively confirm an action or
result of a check; or the check may be performed by someone independent of the
operation. A preferred approach is automation or error proofing devices. This
method can have weakness since it is still dependent on operator.

The process checks need to become part of routine operation. The personnel
conducting the check will ideally understand the importance of the check and also
understand the reaction if the check fails against the criteria.

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NON-STATISTICAL METHODS
Visual process check and checklist Checklist example

Another example would be simple count

of nut plates or rivets that is counted and
then recorded on router or in IT system.
This is required to transact the
completed operations and move part
forward in the process.

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NON-STATISTICAL METHODS
First piece check
The objective of a first piece check is to validate the set-up and quality of a process prior to the full production run.

Prerequisite to a first piece check should be the adherence and confirmation that all other foundational control requirements are
met (e.g., calibration, machine tool diagnostics, tooling within prescribed life limits, acceptable parameter settings, consumables
level, etc.)

It may be called out in a control strategy:

• Whenever a new production lot is started

• Following maintenance/repairs of measurement systems and production equipment, as well as after software updates.
• At a defined interval (e.g., at the start of each shift)
• When tools used to produce the component contour are replaced, (e.g., diamond rolls, profiled grinding/cutting wheels, etc.)

First-piece checking/inspection may be independent from the production method in a number of ways:

• Inspection by an operator other than the person having performed the operation (two person rule); thus avoiding risks due to
bias and other human factors

• Inspection using another inspection tool or inspection method (where possible); thus avoiding/highlighting measurement
discrepancies Inspection using another inspection tool or inspection method (where possible); thus avoiding/highlighting
measurement discrepancies

AESQ – Aerospace Engine Supplier Quality Strategy Group 31

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NON-STATISTICAL METHODS
First piece check
Example 1
A machined dimension with a known adequate level of capability, achieved at first part check may be
deemed sufficient if within 50% of process tolerance; a measurement close to normal limits of operation
may result in adjustment and further measurement to bring the process on target.

Example 2
A process with a tendency towards upward drift may have a zone in the lower region of the specification
band that provides a standard for process acceptance. Continued conformity as the process drifts
naturally through use is provided by a tool life/usage control and typically a run chart or defined limit. The
limits has been determined through a previous tool wear study. If the measurement is outside this zone,
the operator refers to a process plan defined by the organizations to determine appropriate action (e.g.,
tool replacement, or adjustment to the tool life/usage standard).

Example 2 uses two other non-statistical methods to set the defined limits for the first piece checks.

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NON-STATISTICAL METHODS
Test piece evaluation for process capability – Section 5.10
Characteristics and properties are not directly measurable other than through destructive testing. Use of test pieces
processed alongside the product may help to determine the result of the process and also its stability. These test pieces
are tested following processing to validate the products of the process and/or confirm the effectiveness of the other
process controls. A test piece/coupon should be to a defined standard (thus minimizing the variation in the test material
itself).

Examples of processes that use representative test pieces include the following:
• Heat treatment operations
• Surface treatment operations such as shot peening

Examples of evaluation of test pieces include:

• Mechanical property testing using test bars
• Surface contamination coupons in heat treat or thermal processes
• Coupons determining material removal rates in etch and electro-polish processes
• Cast coupons determining chemical analysis of parts from melts
• A forging that has extra material outside the finished part envelope that will be removed for testing.

Note: Test pieces frequently require customer approval and statistical methods are frequently used with results of test
piece data.

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NON-STATISTICAL METHODS
Test piece evaluation for process capability – Section 5.10
Tensile Bar Test Pieces

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FUTURE WEBINARS
From the Process Control Methods SMIG Group
TARGET WEBINAR SUPPORTING SUB-
NO. FUTURE WEBINAR TOPICS BRIEF DESCRIPTION
DATE/TIME LEAD TEAM
Look for these future 1
Process Control Methods - What is RM13006?
Interaction with other AESQ Reference Manuals
12/6/2022 (11 AM US
Eastern) Pete Teti Nicklas Godebu/Marnie Ham
Overview of RM13006 and how it interacts with other
AS13100 reference manuals.

topics in the “Upcoming 1/26/2023 (11 AM U.S.

Cpk values are only as good as what goes into the data
used to calculate Cpk, such as the adequacy of the

Events” page on the

2 What makes a good Process Capability Study? Eastern) Steve Hampton Marnie Ham/Karen Scavotto measurement system and achieving statistical control.
How do we handle process capability for one-sided or
Karen Scavotto/Marnie unlateral tolerances such as true position where
AESQ website: 3
Process Capability Study for True Position (handling
MMC)
2/8/2023 (11 AM U.S.
Eastern) Grant Braun
Ham/Shailesh Shinde/Andrew Maximum Material Condition modifiers may play a
Stout role?
Process controls need not only be statistically based.
Here we explore non-statistical methods such as error-
The use of non-statistically based process control 3/8/2023 (11 AM U.S. Pete Teti/Earl Capozzi/Rudi proofing devices, the PreControl method, and the use
https://aesq.sae- 4 methods Eastern) Paul Gorg Braunieder/Nicklas Godebu of run charts with non statistical limts.
PreControl is a powerpul non-statistical tool that is easy

itc.com/interest-groups 4/11/2023 (11 AM U.S. Steve Hampton/Geoffrey

to get up and running with that can be used to qualify
the set-up of a lot as well as a control for the
5 The Power of Precontrol Eastern) Andrew Stout Carpentier production run.
If you were visiting a supplier and only had time to
carve out one hour for a process control assessment,
5/16/2023 (11 AM U.S. what questions would you ask and where whom would
6 The One-Hour Process Control Assessment Eastern) Pete Teti Geoffrey Carpentier you ask those questions to?
Process Capability indexes without the use of SPC
Control Charts are invalid. Control Charts are the
Why is statistical control a prerequisite for process Andrew Stout/Geoffrey method to monitor and control a process and are a key
7 capability? Target 2nd Qtr (June) Marnie Ham Carpentier/Douglas Dush prerequisite prior to calculating Cp & Cpk.
What happens when the data coming from a process is
Target 3rd Qtr Marnie Ham/Shailesh non-normal? What can be done to accuratly assess
8 Dealing with Non-Normal Data (September) Karen Scavotto Shinde/Andrew Stout process capability? We will show you!
Aerospace component manufacturers the world over
deal with geometric/one-sided features such as runout,
Conducting capability studies for one-sided Marnie Ham/Shailesh flatness, etc. What rules have to change when
9 geometric tolerances Target 4th Qtr (October) Karen Scavotto Shinde/Andrew Stout assessing process capability?

AESQ – Aerospace Engine Supplier Quality Strategy Group 35

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AESQ – Aerospace Engine Supplier Quality Strategy Group

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AESQ – Aerospace Engine Supplier Quality Strategy Group
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AESQ – Aerospace Engine Supplier Quality Strategy Group
This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.