Course overview
TEC’s e-Learning (on-line training) course covers all of the requirements of Process Control Methods using tests, quizzes, case studies and practical exercises. The objective is to qualify practitioners who will be ‘subject experts’ able to understand the theory and be capable of implementing capability studies and process control charts (SPC – Statistical Process Control) – and the training of operators.
downloadable (pdf) Delegate Workbook is included
This course is designed for Quality Engineers, Continual Improvement Practitioners, Six Sigma ‘Belts’ and others involved in process control implementation and/or AAs/AEAs conducting third-party audits involving process control selection and usage.
This course meets the requirements of the aerospace and automotive sectors
Aerospace: the now superseded AS13006 standard and the requirements of AS13100 (Chapter C 21.8) and RM13006 Process Control Methods.
Automotive: the IATF 16949 requirements and the methodologies contained in the AIAG Manual "Stistical Process Control (SPC)".
The e-Learning course includes sessions on basic statistical analysis and graphs, ‘fast-track’ SPC setup using Minitab® and the "Formulae" and "Table of constants" as well as a detailed exploration of the theoretical basis of Control Charts.
Particular attention is given to the selection and use of practical 'variables' and 'attributes' SPC in the automotive and aerospace sectors in which both high/low volumes, complex products and high product mixes are the norm! The role of Taguchi’s Loss Function is addressed to underline the importance of continual process improvement. Deployment of error/mistake proofing devices is explained to prevent operator/process mistakes occurring in the first place.
The relationship between the AS9145, AS9103, AS13003, AS13004, IATF 16949 and SAE J1739 standards are identified and explained – with particular reference to Control plans, PFMEAs and Measurement Systems Analysis (GR&R).
The benefits of SPC are emphasised and 'road-blocks' to deployment are identified and countered!
Course details
Introduction
Download (pdf) of Delegate Workbook
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
Introduction to process analysis
Visualizing the ‘voice-of-the-data’
Exercise: Visualizing the ‘voice-of-the-data’
Checking data for statistical control
Why ‘bell-shaped’?
Exercise: Checking data for statistical control
Basic statistical analysis
Calculating the mean (Xbar)
Calculating the range (R)
Calculating the standard deviation (StDev)
Exercise: Calculating the mean and standard deviation
Standards and terminology
AS13006 – Process Control Methods
Definitions of AS13006 terminology
Quiz: Definitions of AS13006-related terminology
Other AESQ and IAQG standards
Definitions of AS13006-related acronyms
Quiz: AS13006-related acronyms
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
Checking the ‘normality’ of the data
Interpreting the ‘pattern’ of variation
Analytical check on ‘normality’
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 Cpk, 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
Deriving the Statistical Formulae and Table of Constants
Remove the fear!
Understanding the Central Limit Theorem (CLT)
Creating large amounts of normally distributed data
Viewing the histogram of the created data
Calculating the sample means
Viewing the histogram of the ‘sample means’ (Xbar)
Minitab® simulation ~ empirical proof of the CLT (n = 5)
Exercise: Empirical proof of the CLT (n = 10)
Understanding subgroup ‘averages’ and ‘ranges’
Relationship – population StDev and mean range (Rbar)
Relationship – population StDev and mean range (Rbar)
Histogram and statistics of the ‘distribution of range values’
Exercise: Minitab® simulation to establish d2 and d3 (n = 10)
Calculating the σXbar statistic from Rbar data
Control Charts for attributes data
Understanding defects, defectives and attribute data
U Chart
Exercise: Creating a U Chart
P Chart
Exercise: Creating a P Chart
Taguchi’s Loss Function
Preamble
Illustration of Taguchi’s Loss Function
Explanation of Taguchi’s Loss Function
Formula for the Taguchi’s Loss Function (TLF)
Case Study: Using the TLF
Exercise: Using the TLF
Error/Mistake Proofing & the benefits of SPC
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
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
Students successfully completing this e-learning course, and successfully undertaking the quizzes, tests and practical exercises, will receive a training certificate containing the TEC logo (recognised training provider)
Students who successfully complete the course will –
be confident in knowing that their process control and SPC abilities meet the requirements for competency mandated by IATF 16949 and AS13006
be better equipped to maintain on-going compliance with IATF 16949/AS13006 and 'customer-specific' requirements
identify weaknesses in their organization’s QMS documented process for process control and SPC – and be able to address shortcomings
be confident in understanding the mathematical basis of the CLT, SPC Statistical Formulae and the Table of Constants
be equipped to train colleagues and operators to successfully deploy capability studies and all types of SPC
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 Process Control 'practitioner' will have appropriate knowledge/skills and can demonstrate competence
be able to demonstrate conformity to all elements of Capability Studies and SPC to customers
know that the outcomes of their process control and SPC activities will meet the expectations of automotive/aerospace industry customers