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e-Learning: Process control methods (including SPC)

Programme 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.

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Aerospace: the now superseded AS13006 standard and the requirements of AS13100 (Chapter C 21.8) and RM13006 Process Control Methods. TEC are an approved AESQ Training Provider, and this e-Learning course is based on TEC’s PROBITAS Authentication approved course.

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!

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

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
  • E_xercise: 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

Programme 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. The qualification gained will be recognized by the global aero engine manufacturers (AESQ).

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

Testimonials/Press

Albert Einstein is claimed to have said –

"Example isn't another way to teach, it is the only way to teach"

This is the basis of all of our e-Learning courses!

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Buy e-Learning: Process control methods (including SPC)

The course is delivered as an online e-Learning module via the TEC Transnational Ltd learning platform - personalised for learners. Set the number of learners and provide their email addresses at the checkout.

e-Learning: AS13006 - Process control methods (SPC)

£395

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