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Business Process Improvement

Statistical process control

Understanding variation and control charts - a 3-day tutored learning event for quality professionals/technicians

Who should attend

Why you should attend

To gain a basic understanding of

What will I learn?

How to attend

About the event

Day 1 takes delegates through the fundamentals of variation from understanding the difference between common and special/assignable causes to the concept of standard deviation. The question ‘why are control charts used?’ is addressed and the basis of measurement is covered, including the difference between attribute and variable data.

On the afternoon of day 1 delegates are introduced to control charts for variable data – the ‘X bar and R’ chart and on day 2 the ‘X bar and σ’ chart. Day 2 continues with control charts for variable data introducing delegates to the ‘individuals and moving range’ charts.  Day 2 finishes with the concept of ‘process capability’ and 'machine capability' and takes delegates through the process of calculating these useful process indicators.

Day 3 provides an introduction to measurement system analysis, gauge repeatability and reproducibility and the scatter graph. Day 3 concludes with a session on control charts for attribute data, covering both the P chart and the C chart.

Software is used during course exercises and delegates are required to bring laptops to the event.

Structure of the event

Nearly 60% of the time during this event is devoted to workshops where delegates work in syndicates to develop their approach to the issues under discussion. Learning is consolidated through

Customisation of BPIU training courses for in-company presentations

BPIU will customise all courses to fit customers’ specific requirements. We have delivered training for a significant number of the quality tools and techniques and can accommodate most requests.

Course content - day 1

Introducing control charts

Understanding variation

Workshop – Special causes of process variation

Why do we use control charts?

Why do we measure and what do we measure?  Types of data, variable and attribute

Workshop – Types of data

Workshop – Characteristics that are critical to quality

Using histograms

Workshop – Building a histogram from data manually and using Excel

Control charts for variable data

The X bar and R chart, treatment and sorting of data

Workshop – Building an X bar and R chart manually

Workshop – Building an X bar and R chart using software

Course content - day 2

Workshop – Building an X bar and R chart using software continued

Control charts for variable data

Workshop – Building an Individuals and moving range chart manually and using software

Process and machine capability - manual approach

Workshop – Process and machine capability - manual approach

Process and machine capability - using software, includes normal probability plot

Workshop – Process and machine capability using software, includes normal probability plot

Course content - day 3

Measurement system analysis

Gauge repeatability and reproducibility (Gauge R & R)

Workshop – Gauge R & R

Using data analysis tools; scatter graph

Workshop – Building a Scatter graph

Control charts for attribute data - The P chart

Workshop – Building a P chart

Control charts for attribute data - The C chart

Workshop – Building a C chart

Course author and lead tutor: Mike Debenham

Course co-author and co-tutor: David Hutchins experience and approach is founded on his experiences as Production Engineer, Industrial Engineer and Works Manager in the highly competitive field of high volume high precision components for the automotive industry.

Through his intense study of Japanese management systems from the late 1960s onwards, and his friendship with the late Professor Ishikawa (David was invited to write a chapter in the book commemorated to his life and Professor Ishikawa’s only ever visit to Europe was at David’s invitation) He is acknowledged to have pioneered the introduction of several Quality Related concepts into the UK. These include TQM (1972!) Quality Circles (or Kaizen as it is known to some), Just in Time (including all things now called ‘Lean’), Benchmarking (acknowledged in an early DTI publication on the subject), Hoshin Kanri, Root Cause Analysis and Project by Project Improvement. He has been involved with Six Sigma training from its origination at Motorola in the late 1980s.

He likes to work in association with other professionals around the world as a means of cross fertilizing new ideas and to continue the development of the Quality sciences and disciplines.