Capability Studies & Practical SPC – AS9145 & AS9103

The objective of this practical and ‘hands-on’ course and workshop is to empower participants to undertake (and facilitate) process capability studies and operate SPC (Statistical Process Control). The course syllabus covers all of the requirements mandated by AS9103 (Variation management of key characteristics) and AS9145 (Aerospace Series – Requirements for Advanced Product Quality Planning and Production Part Approval Process).

This 2-day course and workshop is highly interactive and uses Case Studies, practical examples, quizzes and group exercises to explain all of the statistical tools in an easy-to-understand manner. Its learning-by-doing – not death-by-slides!

The course timings are -

  • Day #1: 08:30 – 17:00
  • Day #2: 08:30 – 17:00

The course is available on-site (for up to 10 participants) or as a public event (at Woodland Grange Conference Centre).


Introduction to variability and related IAQG requirements (standards)

  • Variability – the irrefutable facts!
  • AS9100:2016 ‘KC’ definition and requirements
  • AS9103:2012 (Rev A) – Variation management of key characteristics
  • AS9145:2016 – Aerospace series – Requirements for advanced product quality planning and production part approval process

Recording, visualizing and analysing process variation

Workshop – recording shop-floor data, and analysing patterns and trends (Case Study #1)

Hands-on exercise involving team participation

  • Recording data on the shop-floor
  • Seeing the ‘voice of the data’ using Run charts and Dot-plots
  • Analysing the ‘voice of the data’ –
  • confirming a normal distribution
  • assessing the ‘central tendency’ and ‘average’
  • identifying out-of-specification points
  • estimating percentage rejects and ppm performance

Introduction to basis statistics

  • Understanding the ‘pattern’ of variation and piece-to-piece variation
  • Drawing histograms and confirming ‘normality’ of the data
  • Understanding central tendency and dispersion graphically

Workshop – Calculating mean (Xbar) and standard deviation (σ) for Case Study #1

Hands-on exercise involving team participation

  • Calculating the mean (Xbar)
  • Calculating the standard deviation (σ)
  • Understanding the properties of the normal distribution
  • Realising the properties of the normal distribution
  • Putting the properties into words

Understanding (statistical) capability

  • Visualising process capability – the car & garage analogy
  • Understanding the 'goal' of process capability
  • Quantifying process capability – Cp and Cpk indices

Workshop – Calculating Cp and Cpk indices for the Case Study #1

Hands-on exercise involving team participation

Improving process performance

  • Objectives of process improvement –
  • Centre the process – targeted on the ‘nominal’
  • Tighten the variation of the process – reduce the StDev (σ)
  • Reduce scrap and rework

Identifying sources of process variation using applicable quality tools

  • Differentiating sources of process variation –
    • Common causes (environmental)
    • Special causes (assignable)
  • Examples of common and special causes in manufacture

Workshop – identifying possible common and special causes

Hands-on exercise involving team participation

  • Identifying the 'four possibilities' for process/product performance –
  • No trouble; Product trouble; Process trouble; Double trouble
  • Implementing process improvement in a logical manner –
    • centre the process
    • reduce variation
  • Understanding the benefits of centring a process (Cpk – Cp)

Workshop – identifying targets for process improvement

Hands-on exercise involving team participation

Quantifying process improvement

  • Operating the process improvement cycle (P-D-C-A)

Workshop – analysing the ‘voice of the data’ plus Cp & Cpk indices calculations after improvement

Hands-on exercise involving team participation

SPC (statistical process control) – Xbar & R Charts

Workshop – understanding the basic principles of control charts

Hands-on exercise involving team participation

  • Understanding the reasons for taking samples
  • Determining sample-based statistics (Xbarbar and Rbar)
  • Workshop – calculating ‘averages’ and ‘ranges’ (Case Study #2)
  • Hands-on exercise involving team participation
  • Drawing ‘averages’ and ‘ranges’ run charts

Tutor simulation – understanding how the constants d2 and d3 are derived

  • Calculating σXbar from Rbar data
  • Creating Xbar and R control charts
  • Understanding and using the table of constants and formulae –
    • n; A2; d2; D3; D4

Workshop – creating Xbar and R control charts (Case Study #2)

Hands-on exercise involving team participation

Test Exercises

Further exercises to test participants' understanding of the principles and practices of data analysis, capability studies and control charts

  • Series of hands-on exercises involving individual participation

Operating SPC

  • Understanding the ‘pre-requisits’ for using control charts
  • Training operators to routinely use SPC
  • Operating Xbar and R charts on the shop-floor
  • Defining ‘out-of-control’ signals
  • Specifying special cause criteria

Assessment of learning achievements

Test Exercises – to ensure that participants can recognise ‘out-of-control’ signals

Choosing the right control chart

Extended Q &A session

Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments during both days

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.

Details/quote

This practical 2-day course & workshop is intended for a broad audience of quality engineers, quality professionals, inspectors, manufacturing engineers and other staff who have to implement AS/EN9103 and undertake capability studies and run SPC on a routine basis.Participants will be empowered to undertake capability studies and run SPC – and facilitate these exercises.

Participants who attend this practical 2-day course and successfully complete the workshop sessions and test exercises will be able to review customer requirements for KCs, undertake capability studies and set-up and operate statistical process control using Xbar and R Charts.

Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

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