2.

Statistical Process Control

Statistical Process Control

A collection of problem solving tools for achieving process stability and improving capability through variability reduction.

Statistical Process Control (SPC) consists of a number of statistical analysis tools that are used to monitor the production process, ensure its stability, and control the quality and consistency of its output. While SPC is used primarily with the manufacture of the product, its relevance to IPD should not be overlooked. SPC is used to ensure that the product is manufactured within tolerance. This is achieved by measuring the output of the process, and comparing this data through statistical analysis to determine the stability of the process. (For a detailed explanation of SPC, see Out of the Crisis by Dr. W. Edwards Deming.) Through the use of SPC tools, the capability of the manufacturing process can be determined, including the tolerances feasible for the process to maintain. The capability of the manufacturing process is an important input to the designers working within the framework of IPD. By knowing the capabilities of the current process, members of the IPT can design with a realistic knowledge of what manufacturing can and cannot accomplish. Adequate training in SPC is well beyond the scope of this guide. However, a knowledge of the most basic elements should be understood to gain an appreciation of the supporting relationship between SPC and IPD. As an overview, the seven most basic SPC tools include:

Seven Basic Tools of SPC

Process Flow Diagram Cause and Effect Diagram Check Sheet Pareto Chart Histogram Scatter Plot Control Chart

PLAN
Identify Process

Use of SPC Tools in the Deming Cycle

Construct Process FLOWCHART

ACT
Type of Cause? CONTROL CHART

Implement change Immediately

BRAINSTORM for Problem Causes Design System Change

Common

Do
CAUSE AND EFFECT
(Fishbone) Analysis

Implement Change

PARETO ANALYSIS
to identify Big problems

NO

YES
Collect and analyze data: CONTROL CHARTS

Determine data collection strategy and process measures

Collect and analyze data: HISTOGRAMS, CONTROL CHARTS, SCATTER PLOTS

Determine Impact On Outcomes Major Cause Identified Improvement Objectives Met?

Return To Beginning Of Cycle

Document And Standardize Improvement

NO

YES

Process Flow Diagrams The process flow diagram is used to express detailed knowledge of the process and identify interactions between the process steps. It is an important tool for documenting and gaining an understanding of basic system operations

Process Flow Diagram

RESOURCE MANAGEMENT DIRECTORATE
VARIANCE ANALYSIS PROCESS FLOWCHART Investment Section Request Apex Report Information
System Directorate

Run Apex

Field
Run SAPAS Organization

Receive SAPAS Report

Investment Section

Sort By System

Received Apex Report

Compare Reports

OK

APPROVED

Temp File

Review Variance Report

QUERIES

Run Variance Analysis

Operating Section

Review Apex Mark

Program Executive Officer

Mark-up Apex

CHANGES

Field
Organization

Answer Query

Field
Organization

Make Changes

Cause and Effect Diagrams The cause and effect diagram is used to identify factors and their associated relationships that may be contributing to a particular problem or situation. The backbone of the chart is the problem being addressed while the primary spines are the causes. The five general categories of causes are materials, machinery, people, environment, and method. Users complete the chart by adding secondary spines that identify potential causes of the problem under each category.

Cause and Effect Diagram

System - CCSS

CAUSE

People

EFFECT

Morale Limited Opportunities Lack of motivation

DLSC Terminals Not enough Old technology

Time required to process cataloging actions

Policy Policy

Equipment

Check Sheets Check sheets are an important tool for collecting, organizing, and analyzing data. Check sheets are frequently useful in identifying recurring problem areas, types, or causes. The data collected in a check sheet may be used as input for a pareto chart or histogram.

Check Sheet
DEFECT 1 PARTS DAMAGED MACHINING PROBLEMS PARTS RUSTED MASKING INSUFFICIENT MISALIGNED WELD ADHESIVE FAILED PAINT OUT OF LIMITS FILM ON PARTS VOIDS IN CASTING IMPROPER TEST PROC. 1 TOTAL 2 4 4 2 1 1 2 4 4 0 0 1 5 2 2 0 2 2 2 1 2 2 1 1 2 1 2 4 1 1 1 2 1 2 3 1 1 2 3 1 1 4 5 1993 6 7 8 9 10 11 12 1 1 2 2 1994 3 1 4 5 6 TOTAL 6 2 5 3 4 6 3 3 2 4 38

Pareto Charts This chart is based on the Pareto principle that states that 80% of the problems are due to 20% of the causes. A Pareto chart is essentially a sorted histogram that is useful in identifying the most significant (i.e., vital few) problems.

Pareto Chart
PROCUREMENT DIRECTORATE AWARD FEE PROCESS MAJOR PROBLEMS.
30 25 20 15 10 5 0 FUNDING REWORK MONITOR CONTR. WORKLOADPKG LOST REPORTS REBUTTAL IN MAIL 27

FUNDING64% of all reported.

Histograms Histograms are useful because they graphically portray the distribution of the data and give the analyst a feel for the central tendency (average) and dispersion (standard deviation/variance).

Histogram
SECURITY ASSISTANCE MANAGEMENT DIRECTORATE
100 100

75

SAMD AVERAGE

75

SAMD AVERAGE

50

25

H A W K

P A T R I O T

S T I N G

L A N D C

50

C H A P

25

H A W K

P A T R I O T

S T I N G

L A N D C

C H A P

DATE OF TASKER TO DATE PRICE REQUESTED

PREPARE CASE FOR COORDINATION

LETTERS OF OFFER AND ACCEPTANCE PROCESS

Scatter Plots Scatter plots are X-Y charts that are useful for uncovering relationships between two variables.

Scatter Plot

300

Pressure

250

200

100 110 120 130 140 150 160 170 180 190 200

Temp

Control Charts Control charts are graphical tools for evaluating process performance, taking into account the natural variability of the process. When properly implemented, control charts can assist in : 1) the identification of special causes of variation, 2) improving process control, 3) identification of trends, and 4) reduction in overall system variability.

Control Chart
MICOM VECP TECHNICAL APPROVAL TIME Number of days.
600 500 400 300 200 100 165 395

UCL 157 MEAN 87 LCL 17

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

VECP NUMBER