Mathews Malnar and Bailey, Inc. Quality engineering, applied statistical consulting, and training services for R&D, product, process, and manufacturing engineering organizations.

Course Description

This course was developed for the Lakeland Community College Quality Managers Network for users of statistical process control (SPC) who have little or no formal training in its use. Students will learn why SPC is used, why it works, and how to set up, operate, and interpret SPC charts. Attribute charts for defectives and defects and variables charts for measurement data will be developed. Hands-on activities will be used to demonstrate real problems and solutions. Students will also be introduced to SPC software, gage error (GR&R) studies, and process capability studies.

Course Format

This 16 hour course is usually taught in four four-hour sessions.

Prerequisite

Students must be able to perform basic mathematical operations including addition, subtraction, multiplication, division, squares, and square roots.

Course Outline

• Introduction
• Seven Tools of Quality
• Cause and effect diagrams
• Process flow charts
• Check and data sheets
• Histograms
• Pareto charts
• Run charts
• Scatter plots
• Introduction to Quality Cost Analysis
• Costs of doing business and quality costs
• Internal failure costs
• External failure costs
• Appraisal costs
• Prevention costs
• Process Improvement with Plan, Do, Check, Act (PDCA)
• Quality Management Systems
• ISO9000
• TS16949
• Descriptive Statistics
• Attribute and variable responses
• Median
• Mean
• Range
• Standard deviation
• Introduction to Shewhart Charts
• Run charts
• Center line (CL) and upper and lower control limits (UCL/LCL)
• Control chart run rules
• Using control charts to manage the process
• Attribute charts
• Defectives (np) and fractions defective (p) charts
• Defects (c) and defect per unit (u) charts
• Variables charts
• Sample mean and range (x-bar and R) charts
• Sample median and range (x-tilda and R) charts
• Individual and moving range (IMR) charts
• SPC Administration
• Sample Size
• Sampling Frequency
• SPC Software
• SPC Audit
• Introduction to Gage Error Studies
• Introduction to Process Capability Studies