Course 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.
a downloadable (pdf) Delegate Workbook is included
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.
Course 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 devices Benefits of practical SPC
Supporters of Statistical Process Control (SPC)
Quiz: Pro & Cons of Statistical Process Control (SPC)
Some relevant 'words of wisdom'
Afterword
Completing and passing the quizzes, tests & exercises
Improving your scores
Qualifications & 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