Basic SPC Tools

Chapter 5 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.
1
Copyright (c) 2013 John Wiley & Sons, Inc.
Basic SPC Tools
• If a product is to meet or exceed customer expectations,
generally it should be produced by a process that is stable or
repeatable.
• More precisely, the process must be capable of operating with
little variability around the target or nominal dimensions of the
product’s quality characteristics.
• Statistical process control (SPC) is a powerful collection
of problem-solving tools useful in achieving process stability
and improving capability through the reduction of variability.
Chapter 5 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2

Basic SPC Tools (“Magnificent Seven”)

Stem-and-Leaf Diagram
Steps for Constructing a Stem-and-Leaf Diagram

Histograms
A histogram is a more compact summary of data than a
stem-and-leaf diagram. To construct a histogram for
continuous data, we must divide the range of the data into
intervals, which are usually called class intervals, cells, or
bins. If possible, the bins should be of equal width to
enhance the visual information in the histogram.
Histograms
Histograms
Check Sheet
• In the early stages of process improvement, it will
often become necessary to collect either historical or
current operating data about the process under
investigation.
• A check sheet can be very useful in this data
collection activity.
• Usually a basis for performing further calculations or
used as a worksheet for data entry into a computer.

Check Sheet

Pareto Chart
• Pareto chart is a variation of the histogram. Data
usually represent different types of defects, failure
modes, or other categories of interest to the
analyst.
• The categories are ordered so that the category
with the largest number of frequencies is on the
left, followed by the category with the second
largest number of frequencies, and so forth.

Pareto Chart

Pareto Chart
• Pareto chart does not automatically identify the most important
defects, but only the most frequent.
• For example, casting voids occur very infrequently (2 of 166
defects, or 1.2%). However, voids could result in scrapping the tank,
a potentially large cost exposure—perhaps so large that casting
voids should be elevated to a major defect category.
• When the list of defects contains a mixture of those that might have
extremely serious consequences and others of much less importance,
one of two methods can be used:
1. Use a weighting scheme to modify the frequency counts.
2. Accompany the frequency Pareto chart analysis with a cost or
exposure Pareto chart.

Chapter 5 16
Cause-and-Effect Diagram
• Once a defect, error, or problem has been identified
and isolated for further study, we must begin to
analyze potential causes of this undesirable effect.
• In situations where causes are not obvious
(sometimes they are), the cause-and-effect diagram
is a formal tool frequently useful in unlayering
potential causes.

Cause-and-Effect Diagram

Defect Concentration Diagram
• A defect concentration diagram is a picture of the unit,
showing all relevant views. Then the various types of
defects are drawn on the picture, and the diagram is
analyzed to determine whether the location of the defects
on the unit conveys any useful information about the
potential causes of the defects.
• When defect data are portrayed on a defect concentration
diagram over a sufficient number of units, patterns
frequently emerge, and the location of these patterns often
contains much information about the causes of the
defects.

Defect Concentration Diagram

Scatter Diagram
• The scatter diagram is a useful plot for identifying
a potential relationship between two variables.
• The shape of the scatter diagram often indicates
what type of relationship may exist between the
two variables.

Scatter Diagram

Scatter Diagram
• Correlation does not necessarily imply causality.
• This apparent relationship could be caused by something quite
different. For example, both variables could be related to a
third one, such as the temperature of the metal prior to the
reclaim pouring operation, and this relationship could be
responsible for what we see in the previous figure. If higher
temperatures lead to higher metal recovery and the practice is
to add reclaim flux in proportion to temperature, adding more
flux when the process is running at low temperature will do
nothing to enhance yield.
• The scatter diagram is useful for identifying potential
relationships. Designed experiments must be used to verify
causality.

Implementing SPC in a Quality Improvement Program
• SPC is most effective when it is integrated into an overall,
companywide quality improvement program.
• Management involvement and commitment to the quality
improvement process are the most vital components of SPC’s
potential success.
• A team approach is also important.
• The basic SPC problem-solving tools must become widely
known and widely used throughout the organization. Ongoing
education of personnel about SPC and other methods for
reducing variability are necessary to achieve this widespread
knowledge of the tools.

• The objective of an SPC-based variability reduction

program is continuous improvement on a weekly,
quarterly, and annual basis.
• SPC is not a one-time program to be applied when the
business is in trouble and later abandoned. Quality
improvement that is focused on reduction of
variability must become part of the culture of the
organization.


An Application of SPC
• Improving quality in a copper plating operation at a printed
circuit board fabrication plant
• This process was characterized by high levels of defects such
as brittle copper and copper voids and by long cycle time. The
long cycle time was particularly troublesome, as it had led to
an extensive work backlog and was a major contributor to poor
conformance to the factory production schedule.
• The DMAIC process was used
• During the define step, the team decided to focus on reducing
flow time through the process
• During the measures step, controller downtown was
recognized as a major factor in excessive flow time


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Chapter 5 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.

Chapter 5 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2

Chapter 5 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 3

Steps for Constructing a Stem-and-Leaf Diagram

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• The objective of an SPC-based variability reduction

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