Course overview
Implementing APQP and PPAP requires an in-depth knowledge of process control methods. TEC’s 2-day course covers the requirements of Process Control Methods using practical exercises, workshops and quizzes. The objective is to qualify practitioners who will be ‘subject experts’ capable of implementing applicable methods and training operators.
This course meets in full the requirements of the now superseded AS13006 standard and the requirements of AS13100 (Chapter C 21.8) and RM13006 Process Control Methods.
In addition to covering AS13006 requirements, particular attention is given to the selection and use of practical SPC (Statistical Process Control) in the aerospace and defence sectors in which low volumes, complex products and high product mixes are the norm!
The relationship between the AS9145, AS9103, AS13003, AS13004 and SAE J1739 standards are identified and explained – with particular reference to Control plans, PFMEAs and Measurement Systems Analysis (GR&R).
Course details
The requirements of AS13006 are covered in a systematic and practical manner using quizzes, team and individual exercises –
AESQ and IAQG – standards
AS13006 requirements (clauses)
Variability – the irrefutable facts!
Process variation – the irrefutable facts!
Process variation – product characteristics
Identifying types of variation and understanding sources of variation
Workshop-1
Differentiating sources of process variation
Identifying all sources of process variation
Judging a process in a state of statistical control
Stable and controlled ‘operating environment’
Common causes of variation
Team exercise – examples of common causes
Special causes of variation
Team exercise – examples of special causes
4.1 Process control methods requirements overview
Process control methods overview
Foundational activities
Individual exercise – unfamiliar acronyms
Pre-operation process checklist
First piece check (aka ISIR)
AS13006 interfaces with IAQG/SAE standards
Process control activities overview – AS13006
Mandated AS13006 activities
Introduction to basic statistical analysis
Workshop-2
Creating the shaft diameter on a CNC lathe
The first 10 subgroups (diameter measurements)
Visualizing the ‘voice of the data’ (Run Chart & Histogram)
Class quiz – visualizing the ‘trends’ (Run Char
Class quiz – does the data look ‘bell-shaped’? (Histogram)
Class quiz – is the data normally distributed? (Anderson-Darling)
Team exercise – what did you make of the data?
Understanding the ‘pattern’ of variation
Properties of the normal distribution
Class quiz – central tendency and dispersion
Calculating mean (Xbar) and standard deviation (σ)
Calculating the mean (Xbar)
Calculating the standard deviation (σ)
Understanding the StDev (σ) formula
Individual exercise – calculating Xbar and StDev
Understanding process capability
Workshop-3
Visualizing process capability
Illustration – ‘non-capable’ process (centred)
Illustration – ‘capable’ process (centred)
Process capability – Cp (best case)
Individual exercise – Cp calculation
Process capability – Cpk (worse case)
Individual exercise – Cpk calculation
Team exercise – Cp and Cpk of shaft diameters
Minitab® – Cp and Cpk calculations
Process capability – AS9145 requirements
Benefits of centring a process (Cpk – Cp)
Cp & Cpk and Pp & Ppk differences explained
Subgroup size = 50 (Cmk index)
Performance levels – process capability/yield
Understanding how statistical control limits (LCL & UCL) are determined
Workshop-4
Control charts – the basic principles
Understanding the reasons for taking samples
Representation of the ‘population’ parameters and ‘sample’ statistics
Using samples – the ‘central limit theorem’
Minitab® simulation – population/sample statistics
It’s easier to work with ‘averages’ and ‘ranges’
Relationship – population σ – mean range (Rbar)
Relationship – population σ – StDev range (σR)
Minitab® simulation to establish d2 and d3 (n = 5)
Histogram of our ‘population’ data values
Histogram of the ‘range statistics’
What are the implications?
Calculating σXbar from Rbar data
Creating Xbar control charts
Creating Rbar control charts
Table of constants for Xbar and R control charts (AS13006 TABLE 8-4)
Setting up and monitoring statistical control methods
Workshop-5
Steps in setting up statistical process control
Address common causes
(1) Collect data at the shop-floor
(2) Graphical assessment (i.e. Run Chart)
(3) Confirm ‘normality’ from data – histogram
(4) Confirm ‘normality’ from data – by analysis
(5) Determine process capability index (Cpk)
If non-capable determine/fix all causes
The first 10 subgroups (diameter measurements)
(1) If non-capable improve the process
(2) Again, confirm ‘normality’ – by analysis
(3) Select control method – Xbar & R (Variables)
WARNING – Xbar & R (for noncapable process)
Select control method – I-MR Chart (variables)
Monitor using the 8 industry standard tests
Team exercise – using the 8-tests with I-MR Chart
Select control method – P Chart (attributes)
Select control method – NP Chart (attributes)
Cp & Cpk and Pp & Ppk differences explained
4.2 Applicability
Process control methods and their usage
Process and product characteristics
Understanding characteristic (data) ‘types’
Data collection essentials
Manually maintained Xbar & R chart (circa 1983)
Individual exercise – process/product characteristics
Proactive vs. Reactive process control
Benefits of proactive process control and SPC
Excuses for not implementing SPC
Team exercise – ‘counter-responses’ to excuses
Identification of characteristics – APQP ‘roadmap’
Control plan – the ‘pivotal’ document
Characteristics and their control methods
Individual exercise – use of APQP and the ‘tools’
Products within families (components/assemblies)
4.3 Organizational quality system requirements
QMS conformity with AS9100 and AS9145
QMS additional AS13006 requirements (audit checklist – Appendix B)
4.4 Training and competency
Knowledge/Skills of tools and methodologies
Individual exercise – Knowledge/Skills competency (practitioner & APQP teams)
4.5 Process control prerequisites
Definition of a measurement system
Factors affecting measurement systems (SWIPE)
Components of measurement variation
Understanding measurement system analysis
Individual exercise – use of MSA methodologies?
Identification of product/process characteristics
Individual exercise – determination of KCs & Cis
4.6 Process control method selection
Relating control charts to data types
Determining the appropriate control chart
Team exercise – selecting appropriate control chart
Alternatives to AS13006 control activities
Risk mitigation using multiple control methods
Indirect control activities
Process control methods using automation
Work instructions to operate the controls
4.7 Process analysis and improvement
Follow the Deming cycle (P-D-C-A)
4.7.1 Plan data collection
Data collection forms – data types
Planning data collection (apply to all KCs and CIs)
Reminder: characteristic (data) categories
Steps in setting up statistical process control
4.7.2 Generate process data
Process control methods using automation
Data collection – 25 subgroups (size 5)
Data graphical analysis – 25 subgroups
Run chart – data collected in time sequence
Team quiz – what would be your decision?
Pre-control chart
Pre-control charts – operational rule variants
Class quiz – what would be your decision?
4.7.3 Analyze data
Basic checks for statistical control
Process capability analysis (focus on Cpk)
Process capability ‘Sixpack Report’ for process
Class quiz – standard tests (special cause variation)
Team exercise – chamber diameters (I-M Chart)
4.7.4 Conduct improvement
Process condition – unstable, stable and capable
Process condition – unstable, stable and capable
Data graphical analysis – 25 subgroups
Process capability analysis (focus on Cpk)
Process capability ‘Sixpack Report’ for process
4.8 Process monitoring and control
Control plan finalized – including reaction plans
Record all evidence on the shop floor (Event Log)
4.9 Process change management
Changes to manufacturing process
Who should attend
This course is designed for Quality Engineers, Continual Improvement Practitioners, Six Sigma ‘Belts’, QMS Internal Auditors and others involved in process control implementation and/or AAs/AEAs conducting third-party audits involving process control selection and usage.
Deliverables & benefits
Students attending this course, and successfully passing the written examination, will receive a training certificate containing the TEC logo.
TEC's course will quality and empower personnel to implement and use powerful process control tools to the benefit or their organizations.
The course includes capability analysis, setting up/operating control charts, problem solving, process improvement, and error/mistake proofing.