STATISTICAL PROCESS CONTROL AND CAPABILITY

INTRODUCTION

Maintaining stable and efficient processes requires a data-driven approach to monitoring variation and performance. Statistical Process Control (SPC) provides the tools to distinguish between natural and special cause variation, detect process shifts, and evaluate process capability.

This one-day course explores SPC principles, control charts, process capability, and performance analysis. It will cover the different types of control charts, their appropriate use cases, and introduce CUSUM charts for proactive detection of process changes. Participants will also learn about process capability analysis, including the challenges of meeting targets and Six Sigma methodologies.

Participants will have the opportunity to bring their own data and create simple XmR process control charts from first principles.

This John Varlow | Training and Consultancy course will cover:

✔ The importance of understanding data before analysis
✔ Analyzing time series data and related techniques
✔ Recognizing issues with traditional visualization methods
✔ Differentiating between natural and special cause variation
✔ Exploring different types of process control charts and their applications
✔ Understanding the statistical principles behind control charts
✔ Applying SPC rules for detecting "out of control" processes
✔ Introducing CUSUM charts for early detection of process changes
✔ Discussing process capability analysis and its challenges
✔ Understanding the relationship between SPC and Six Sigma methodologies
✔ Exploring the applicability of SPC techniques in different work areas

COURSE OBJECTIVES

By the end of this one-day course, participants will:

✔ Develop a strong understanding of time series data and its role in SPC
✔ Recognize common issues in process visualization and improve accuracy
✔ Differentiate between natural and special cause variation in process data
✔ Select and apply the appropriate process control chart for specific situations
✔ Gain insight into the statistical principles behind control charts
✔ Learn how to apply SPC rules for detecting "out of control" conditions
✔ Understand CUSUM charts and their role in proactive process monitoring
✔ Explore process capability analysis and the challenges of meeting targets
✔ Understand how SPC techniques apply across different industries and work areas

TRAINING METHODOLOGY

This session is interactive and hands-on, blending theory with real-world application. Participants will engage in:

✔ Guided exercises in creating process control charts
✔ Group discussions on data interpretation and visualization challenges
✔ Step-by-step analysis of process variation using real-world examples
✔ Opportunities to apply SPC techniques to participants' own datasets

Participants will have the option to use Microsoft Excel for chart creation, though manual calculations will also be demonstrated for a fundamental understanding of SPC principles.

WHO SHOULD ATTEND?

This course is ideal for professionals responsible for monitoring, analyzing, and improving processes using SPC techniques. It is particularly relevant for:

✔ Quality & Process Improvement Specialists
✔ Operations & Production Managers
✔ Business Analysts & Data Analysts
✔ Manufacturing & Engineering Teams
✔ Healthcare & Public Sector Professionals monitoring performance data
✔ Anyone involved in process control, Six Sigma, or performance improvement

Pre-requisites:

✔ Basic numeracy skills
✔ Use of a calculator (please bring one with you)
✔ Microsoft Excel installed on client machine (optional but recommended)

COURSE OUTLINE

1. Understanding Time Series Data and Data Visualization Challenges

✔ Recognizing the importance of data structure in SPC
✔ Identifying issues in traditional data visualization
✔ Exploring alternative methods for clearer insights

2. Natural vs. Special Cause Variation

✔ Understanding the difference between routine variation and process shifts
✔ How to distinguish between corrective action and unnecessary intervention

3. Types of Process Control Charts

✔ Introduction to different types of control charts and their uses
✔ Selecting the right chart for different data types
✔ Creating XmR charts from first principles

4. The Statistics Behind Control Charts

✔ Understanding mean, variation, and control limits
✔ How sample size affects control chart accuracy

5. Rules for Detecting "Out of Control" Processes

✔ Applying SPC rules to identify process instability
✔ Recognizing common patterns that indicate process shifts

6. Using CUSUM for Proactive Process Monitoring

✔ How CUSUM charts improve early detection of changes
✔ When to use CUSUM instead of traditional control charts

7. Process Capability & Performance Analysis

✔ Introduction to process capability indices
✔ Understanding why meeting targets can be misleading
✔ The relationship between SPC, process capability, and Six Sigma

DURATION

⏳ 1 Day

This course provides a comprehensive yet practical approach to SPC, ensuring participants gain both theoretical knowledge and hands-on experience in process control and capability analysis.

CERTIFICATION

Upon successful completion of this course, participants will receive a John Varlow | Training and Consultancy Certificate of Completion.