e-Learning: Capability Studies & Practical SPC for Operators

Programme overview

TEC’s e-Learning course has been specifically designed for operators and shop-floor inspectors who need to understand and undertake process capability studies and practical SPC (Statistical Process Control).

All of the requirements of AS13006 Process Control Methods relating to capability studies and variables control charts are covered in a practical manner using quizzes, tests, case studies and ‘real-world’ exercises.

TEC are an approved AESQ Training Provider, and this e-Learning course is based on TEC’s PROBITAS Authentication approved course.

This e-Learning course includes sessions on basic statistical analysis and graphs, ‘fast-track’ capability studies and SPC setup/operation using manual methods and Minitab®.

Note: if you don’t have a copy of Minitab® – download a FREE 30-day trial

Students can work at their own pace: leave/restart the course as required and backtrack as necessary. Every modules includes quizzes/tests/exercises which are taken individually and in private. In fact, the entire course may be taken anonymously – for an initial ‘dry-run’. Hints and advisement are always provided to guarantee correct understanding of the principles and practices involved.

The e-Learning course can be taken on any devices, anywhere and at any time. Only requires ‘reasonable’ internet access. There is no special training room needed and no need for face-to-face contact.

experience has shown that the entire e-course can be completed in 8-hours

All students successfully completing the course and test-of-understanding will receive a Training Certificate containing TEC’s logo as tangible evidence of their newly gained expertise. Their new competencies can be used immediately to the benefit of their company.

Programme details

Understanding variability and the causes

  • Process variation – the irrefutable facts!
  • Process variation – causes of variation
  • Sources of variation
  • Common causes of variation
  • Test: Identifying common causes
  • Special causes of variation - Test: Identifying special causes

Foundational activities

  • Preliminary activities
  • Pre-operation process checklist
  • Pre-operation process checklist
  • Test: Preliminary activities

Basic statistical analysis

  • Calculating the mean (Xbar)
  • Calculating the range (R)
  • Calculating the standard deviation (StDev)
  • Exercise: Calculating the mean and standard deviation

Fundamental statistical properties

  • Properties of the normal distribution
  • Test: Properties of the normal distribution

Understanding, quantifying and visualizing the ‘voice-of-the-customer’ with Minitab®

  • Defining the ‘voice-of-the-customer’
  • Exercise: Quantifying the ‘voice-of-the-customer’
  • Exercise: Visualizing the ‘voice-of-the-customer’
  • Overview of Minitab® components
  • Personal assignment: Using Minitab® for basic statistical analysis & graphs

Improving process performance

  • Standardizing manufacturing
  • Exercise: Using Minitab® to analyse improved process
  • Exercise: Checking the effectiveness of improvement
  • Interpreting the ‘pattern’ of variation

Understanding and quantifying process capability

  • Visualizing process capability
  • Illustration: A ‘capable’ process (centred – best case)
  • Calculating process capability – Cp (best case)
  • Test: Cp calculation
  • Calculating process capability– Cpk (worse case)
  • Test: Cpk calculation
  • Minitab® Cp and Cpk calculations
  • Process capability (Cpk) – AS9145 requirements
  • Benefits of centring a process (Cpk ≈ Cp)

Process control activities

  • The “journey to process capability”
  • Foundation activities
  • Statistical control
  • Centre on the nominal
  • Reduce variation
  • Formal check on ‘normality’
  • Capability Study
  • Exercise: evaluating new CNC performance

Understanding the difference between Cp, Cpk, Pp and Ppk

  • Different indices of capability
  • Usage of the different indices
  • Quiz: Understanding process capability indices

Control charts

  • Introduction to control charts
  • Control charts for variable data
  • Control charts for attribute data
  • Quiz: Control charts and their usage
  • The basic principle of (variables) control charts

Setting up and deploying an Xbar-R Control Chart using Minitab®

  • Minitab® data entry – overview & illustration
  • Exercise: Xbar-R Control Chart (Minitab®)
  • Manual calculation and data entry – overview & illustration
  • Exercise: Xbar-R Control Chart (Manual calculation)

Practical elements of Control Charts

  • Report details
  • Event Log
  • Industry tests for statistical control
  • Quiz: The industry tests for statistical control
  • Choosing appropriate industry tests

Other Control Charts for variable data

  • Xbar-S Control Chart
  • Exercise: Setting up an Xbar-S Chart
  • I-MR Control Chart
  • Exercise: Setting up an I-MR Chart

Error/Mistake Proofing

  • Defects and human factors
  • Understanding different types of defects and their causes
  • Deploying countermeasures – error/mistake proofing in controls
  • Forms of error/mistake-proofing devices
  • Quiz: Identifying the benefits of error/mistake proofing devicesBenefits of practical SPC

  • Supporters of Statistical Process Control (SPC)

  • Quiz: Pro & Cons of Statistical Process Control (SPC)
  • Some relevant 'words of wisdom'


  • Completing and passing the quizzes, tests & exercises
  • Improving your scores

Programme benefits

Operators/inspectors who successfully complete the course will –

  • be confident in knowing that their process control and SPC abilities meet customer expectations
  • be better equipped to maintain on-going compliance with 'customer-specific' requirements for both capability studies and practical SPC
  • identify weaknesses in their organization’s QMS documented process for process control and SPC – and be able to address shortcomings
  • be able to accrue IRCA CPD points because of the highly structured nature of this course

Their organization will –

  • be confident that their newly qualified operators/inspectors will have appropriate knowledge/skills and can demonstrate competence
  • be able to demonstrate conformity with 'customer-specific' requirements for both capability studies and practical SPC
  • know that the outcomes of their process control and SPC activities will meet the expectations of aerospace/defence industry customers

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