Process Control Design Using SPC
2 Days

Course Description and Audience:
Course is deigned for Engineers, Scientists and Managers who have direct responsibility
for designing and implementing closed loop process controls.  The course covers the
basic concepts sensor design, selection of alarms, control logic and out of control
action plan.  Statistical process control charts for variables and attributes and
associated limit calculations are also presented.

 

Course Objectives:
Upon completion of the course the participants will be able to:

  1. Understand the language and compute the basic statistics associated with SPC.
  2. Apply the ten process control requirements to achieve process control.
  3. Determine rational subgroup formation, sample size and frequency.
  4. Select appropriate control chart for process control requirements.
  5. Compute appropriate control limits.
  6. Select the appropriate SPC Charts.
  7. Design appropriate OCAPs.
  8. Determine process capability.                                       
  9. Describe the roles and responsibilities for using SPC.
  10. Use the analytical software to analyze process variation patterns, generate
    SPC charts and determine process capability.

Software:  JMP, Excel     
Prerequisites: ESDA is recommended

Detailed Course Outline:

Introduction and Basic Statistics                                           
SPC a basis for control
Basic statistics 
Normal distribution
Standard error of the mean
Central limit theorem

Ten Requirements for Designing Effective Process Control
Clear product specifications 
Effective metrology 
Process characterization
Sampling plan 
Control chart selection (variables and attributes)
Alarms and out of control action plans (OCAP)          
Process documentation 
Operator and engineering training 
Database
Routine line audits 

Process Capability
Determining process stability prior to computation of capability
Cp and Cpk
Application of specifications and yield estimation 
Tests for normality
Distribution fitting for non-normal parameters                   
Sigma and z as measures of process capability  
Pareto plots and measures of process capability for attributes  
   
Process Control Implementation Roles and Responsibilities
Management 
Process engineer 
Process control specialist
Supervisor
Operator