Statistical Process Control Training Course

Module 1: Foundations of Quality Management and Variation

• The concept of Quality and its evolution (Inspection → Quality Control → TQM)
• The role of Dr. Walter Shewhart and the PDCA cycle
• Understanding process variation: Common cause vs. Special cause variation
• Statistical Control: Defining a stable and predictable process
• The economic benefits of process stability and capability
• Practical session: Analyzing a dataset to distinguish between the two types of variation using run charts

Module 2: Fundamentals of Control Charts

• The basic structure of a control chart: Center Line (CL), Upper Control Limit (UCL), Lower Control Limit (LCL)
• The theoretical basis for control limits (3-Sigma limits)
• Rational Subgrouping: Principles and methods for collecting data
• Selection criteria for the appropriate type of control chart
• The importance of the process being in a state of statistical control
• Practical session: Determining appropriate subgroup size and collecting baseline data for a new control chart

Module 3: Control Charts for Variable Data (I-MR, X̄-R)

• Introduction to Variable (measurement) data charts
• Individual and Moving Range (I-MR) charts for individual observations
• Subgroup Average (X̄) and Range (R) charts for subgrouped data
• Formulas for calculating the Control Limits for X̄ and R charts
• Interpreting out-of-control signals and Western Electric rules
• Practical session: Constructing and interpreting X̄ and R charts for a manufacturing process using statistical software

Module 4: Control Charts for Variable Data (X̄-S and Advanced Techniques)

• The X̄ and S (Standard Deviation) charts: When to use S instead of R
• Formulas for calculating the Control Limits for X̄ and S charts
• Analysis of non-normal data and transformation techniques
• Dealing with control limits when the process mean and standard deviation are unknown
• Variable charts for non-normal distributions (e.g., transformation or specialized charts)
• Practical session: Constructing and interpreting X̄ and S charts for high-volume data using statistical software

Module 5: Control Charts for Attribute Data (p and np Charts)

• Introduction to Attribute (count/categorical) data charts
• The Binomial Distribution as the underlying theory for p and np charts
• p chart: Monitoring the fraction nonconforming (proportion defective)
• np chart: Monitoring the number nonconforming (number defective) when sample size is constant
• Dealing with varying subgroup sizes in p charts
• Practical session: Constructing and interpreting p and np charts for a quality inspection process

Module 6: Control Charts for Attribute Data (c and u Charts)

• The Poisson Distribution as the underlying theory for c and u charts
• c chart: Monitoring the number of defects (nonconformities) when area/opportunity is constant
• u chart: Monitoring the number of defects per unit when area/opportunity is variable
• Formulas for calculating Control Limits for c and u charts
• Practical applications of c and u charts in service industries (e.g., call center errors)
• Practical session: Constructing and interpreting c and u charts for surface defect analysis

Module 7: Process Capability Analysis (Cₚ, Cₚₖ)

• Differentiating between Statistical Control and Process Capability
• Defining customer specification limits (USL and LSL)
• Calculating and interpreting the Potential Capability Index (Cₚ)
• Calculating and interpreting the Process Performance Index (Cₚₖ)
• Interpreting Six Sigma process metrics and DPMO (Defects Per Million Opportunities)
• Practical session: Performing a full Process Capability analysis and comparing Cₚ and Cₚₖ for a critical dimension

Module 8: Advanced Process Monitoring: Cusum and EWMA Charts

• Limitations of standard Shewhart charts for detecting small shifts
• Cumulative Sum (CUSUM) charts: Design and V-mask interpretation
• Exponentially Weighted Moving Average (EWMA) charts: Design and weighting factor
• When and why CUSUM and EWMA are superior for shift detection
• Comparison of the sensitivity and complexity of Shewhart, CUSUM, and EWMA
• Practical session: Setting up and monitoring a process using a CUSUM chart to detect a minor but critical shift

Module 9: Pre-Control and Short Run SPC Methods

• Introduction to Pre-Control: Simple visual method for controlling setup and stability
• The use of Pre-Control for processes with tight tolerances
• Challenges of applying traditional SPC to low-volume, Short Run production
• Techniques for Short Run SPC: Standardizing the data and using Z-charts
• Short Run Attribute charts and tracking defect patterns
• Practical session: Applying the Short Run SPC method (using Z-charts) to monitor a low-volume manufacturing process

Module 10: SPC Implementation, Management, and Reporting

• Steps for successful SPC implementation within an organization
• Training and engaging personnel in the use and interpretation of control charts
• Integrating SPC with other quality systems (e.g., ISO, Lean, Six Sigma)
• Best practices for reporting and communicating SPC results to management
• Developing and documenting Out-of-Control Action Plans (OCAPs)
• Practical session: Developing an OCAP for a given out-of-control scenario and presenting a comprehensive SPC summary report

Requirements:

• Participants should be reasonably proficient in English.
• Applicants must live up to Armstrong Global Institute admission criteria.

Terms and Conditions

1. Discounts: Organizations sponsoring Four Participants will have the 5th attend Free

2. What is catered for by the Course Fees: Fees cater for all requirements for the training – Learning materials, Lunches, Teas, Snacks and Certification. All participants will additionally cater for their travel and accommodation expenses, visa application, insurance, and other personal expenses.

3. Certificate Awarded: Participants are awarded Certificates of Participation at the end of the training.

4. The program content shown here is for guidance purposes only. Our continuous course improvement process may lead to changes in topics and course structure.

5. Approval of Course: Our Programs are NITA Approved. Participating organizations can therefore claim reimbursement on fees paid in accordance with NITA Rules.

Booking for Training

Simply send an email to the Training Officer on training@armstrongglobalinstitute.com and we will send you a registration form. We advise you to book early to avoid missing a seat to this training.

Or call us on +254720272325 / +254725012095 / +254724452588

Payment Options

We provide 3 payment options, choose one for your convenience, and kindly make payments at least 5 days before the Training start date to reserve your seat:

1. Groups of 5 People and Above – Cheque Payments to: Armstrong Global Training & Development Center Limited should be paid in advance, 5 days to the training.

2. Invoice: We can send a bill directly to you or your company.

3. Deposit directly into Bank Account (Account details provided upon request)

Cancellation Policy

1. Payment for all courses includes a registration fee, which is non-refundable, and equals 15% of the total sum of the course fee.

2. Participants may cancel attendance 14 days or more prior to the training commencement date.

3. No refunds will be made 14 days or less before the training commencement date. However, participants who are unable to attend may opt to attend a similar training course at a later date or send a substitute participant provided the participation criteria have been met.

Tailor Made Courses

This training course can also be customized for your institution upon request for a minimum of 5 participants. You can have it conducted at our Training Centre or at a convenient location. For further inquiries, please contact us on Tel: +254720272325 / +254725012095 / +254724452588 or Email training@armstrongglobalinstitute.com

Accommodation and Airport Transfer

Accommodation and Airport Transfer is arranged upon request and at extra cost. For reservations contact the Training Officer on Email: training@armstrongglobalinstitute.com or on Tel: +254720272325 / +254725012095 / +254724452588