3.spc course outline

CQE Training & Consultancy (IP 0187064-K)
Registered Office : No. 46, Lorong Bintang, Taman Tasik Permai, 34000 Taiping, Perak. Malaysia.
Operating Office : No. 85A (1st
. Floor), Jalan Barrack, 34000 Taiping, Perak. Malaysia.
T : +605-805 2722 / +605-808 8028 F : +605-805 2721 M : +6012-505 2720 / +6012-550 2721
E : cqetraining@gmail.com or kuangkh@cqetraining.com W : http://www.cqetraining.com B : http://cqeblog.blogspot.com
Prepared by : Mr . Eddie Kuang Copyright © 2001-2015. All Rights Reserved. - 1 -
STATISTICAL PROCESS CONTROL (SPC)
(PUBLIC / IN-HOUSE TRAINING PROGRAMME)
Introduction
Statistical Process Control (SPC) was pioneered by Walter A. Shewhart and taken up by W. Edwards
Deming with significant effect by the Americans during World War II to improve industrial production.
Deming was also instrumental in introducing SPC methods to Japanese industry after that war. Dr. Shewhart
created the basis for the control chart and the concept of a state of statistical control by carefully designed
experiments. While Dr. Shewhart drew from pure mathematical statistical theories, he understood data from
physical processes never produce a "normal distribution curve" (a Gaussian distribution, also commonly
referred to as a "bell curve"). He discovered that observed variation in manufacturing data did not always
behave the same way as data in nature. Dr. Shewhart concluded that while every process displays variation,
some processes display controlled variation that is natural to the process, while others display uncontrolled
variation that is not present in the process causal system at all times. When a process is in control, it becomes
very important to determine how capable of the manufacturing process is meeting the customer’s
requirements. Unfortunately, many questions exist about how these studies should be done, and if done
correctly, what the results actually mean. This course is to clarify the above confusion. The application of
relevant computer software such as Minitab, MS Excel and/or SQCPack also will be covered in simplifying
the statistical calculation and analysis.
Learning Outcomes/Objectives
This course is specifically developed to provide participants in the manufacturing industry the basic real-time
statistical techniques for process control and improvement. Participants will gain knowledge of the basic
fundamentals of process improvement, concept of variation, statistical control and other simple but powerful
statistical techniques. At the end of this programme, participants will be able to :-
 Identify specific area in your company where quality and productivity improvement
methodology can be applied.
 In-depth understanding of the concepts underlying SPC.
 Examine necessary steps in implementing SPC methods into your company effectively.
 Knowledge of process characterization, control and improvement flow.
 Measurement of effectiveness and efficiency of SPC.
 The application of Minitab, MS Excel and SQCPack for SPC related analysis.
Also available as
in-house programme
SBL
Scheme

T : +605-805 2722 / +605-808 8028 F : +605-805 2721 M : +6012-505 2720 / +6012-550 2721
Program Contents
Session #1 - Fundamentals of Process Improvement
 Deming Management Philosophy.
 Definitions of Statistics, Process, Control.
 Elements of a Process.
 Concept of Detection and Prevention.
 Concept of Variation
 Types of variation
 Stable versus Unstable Process
 Common/Natural versus Special/Assignable Causes
 Behaviour of Sample Statistics
 Exercise.
Session #2 - Deriving Information from Data
 Histogram and Frequency Distribution Curve.
 Normal Distribution and Its Characteristics.
 Sample versus Population.
 Standardized Normal Distribution.
 Process Sampling.
 Information from Distribution.
 Measures of Location / Skewness and Dispersion / Variation.
 Exercise.
Session #3 - Statistical Process Control
 Concepts behind Control Chart.
 Relationship between Frequency Distribution and Control Charts.
 Type of Control Charts
 Variable Control Charts
 Attribute Control Charts
 Exercise.
Session #4 - Variable Control Charts
 Basic Variable Control Charts - Xbar-R, Xbar-S, Xi-MR, Median-R, Pre-Control &
Cumsum Chart
 Subgrouping Techniques.
 Identification of Critical Process Parameters and Product
Characteristics for Control Charting.
 Construction of Variable Control Charts.
 Data Collection and Calculation.
 Calculating Control Limits.
Using MINITAB
and MS Excel

T : +605-805 2722 / +605-808 8028 F : +605-805 2721 M : +6012-505 2720 / +6012-550 2721
 Difference between Specification Limits and Control Limits.
 Control Charts Interpretation.
 Out-of-Control Corrective Action.
 Characteristics of an Effective Control Chart.
 Exercise
Session #5 - Attribute Control Charts
 p, np, c and u Attribute Control Charts.
 Construction of Attribute Control Charts.
 Data Collection and Calculation.
 Calculating Control Limits.
 Control Charts Interpretation.
 Out-of-Control Corrective Action.
 Exercise.
Session #6 - Process Capability Study
 Importance of Stability.
 Definition of Statistical Control.
 Definition of Capability Ratio and Capability Indices.
 Calculation of Capability Ratio and Capability Indices - CR, Cp,
Cpl, Cpu, Cpk, Pp, Ppk and Cpm.
 Interpretation of Capability Ratio and Indices.
 Transformation of Process Capability Information into
Graphical Illustration for better understanding.
 Estimating Process Yield and Rejection Rate, ie. Zu and Zl calculation
 Strategies to improve Process Capability.
 Exercise.
Session #7 – Assessment / Test
 Preliminary Test.
 Quiz 1.
 Quiz 2.
 Quiz 3.
 Control Chart and Frequency Distribution Exercise.
 Final Test.

T : +605-805 2722 / +605-808 8028 F : +605-805 2721 M : +6012-505 2720 / +6012-550 2721
Who should attend
Managers, Engineers, Executives, Quality Practitioners and any member of an organisation who is from
Process, Research and Development, Quality and Production will find this course relevant and beneficial to
their job function.
Methodology
The program would be conducted by using the following
materials / aids :-
 Course Notes
 OHP / LCD
 Video Showing
 Case Study & Group Activities (with Minitab, MS Excel and/or SQCPack software)
 Lecturettes
Duration
2 days
Participants
Max ~25 pax (please brings along scientific calculator, computer facilities installed with Minitab and MS
Excel software)
Costumer Lists
Mabuchi Motor (M) Sdn. Bhd.
Hume Fibre Board Sdn. Bhd.
BenQ Technology (M) Sdn. Bhd.
Amsteel Berhad, Bukit Raja Klang.
Megasteel Sdn. Bhd., Banting.
Silverstone Berhad, Kamunting, Taiping.
CS Opto Semiconductor (M) Sdn. Bhd.
Western Digital (M) Sdn. Bhd.
Konical Minolta (M) Sdn. Bhd.
Yan Jin Sdn. Bhd, Bukit Tengah Penang
Rubberex Berhad, Ipoh Perak
Finisar (M) Sdn. Bhd, Ipoh Perak
Camcar Textron (M) Sdn. Bhd. (now known as Textron Fastening (M) Sdn. Bhd.)
Sepang Institute Technology Corporate Learning Centre, Klang
Samsung Electronics Display (M) Sdn. Bhd.

T : +605-805 2722 / +605-808 8028 F : +605-805 2721 M : +6012-505 2720 / +6012-550 2721
Osram Opto Semiconductor (M) Sdn. Bhd.
Chunghwa Picture Tubes (M) Sdn. Bhd. (QEDP Training Programme)
Western Digital (M) Sdn. Bhd. (CQE Training Programme)
Texas Instruments (M) Sdn. Bhd. (QEDP Training Programme)
S.E.H. Malaysia Sdn. Bhd.
STATS ChipPAC Malaysia Sdn. Bhd.
Agilent Technologies (M) Sdn. Bhd.
Unisem Berhad
IDS Electronics Sdn. Bhd.
Carsem Semiconductor Sdn. Bhd.
and etc…

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