# QUAL08001 2019 Statistical Process Control

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**Description**

Provides the student with a comprehensive understanding and knowledge of the use of statistical methods and techniques for monitoring and controlling processes.

### Learning Outcomes

*On completion of this module the learner will/should be able to;*

**1.**

Use and apply the basic problem solving techniques of quality to analyse data.

**2.**

Apply qualitative tools for problems solving, prioritising problems and improving processes.

**3.**

Develop, plot and analyse both variable and attribute Shewhart control charts.

**4.**

Construct and use a EWMA chart

**5.**

Apply short run and standardised control charts.

**6.**

Conduct process and gauge capability analysis and develop the capability indices.

**7.**

Conduct acceptance sampling by attribute and by variable data using ANSI/ASQC Z1.4 and ANSI/ASQC Z1.9 respectively.

**8.**

Apply skip-lot, continuous and chain sampling procedures.

### Teaching and Learning Strategies

Real world examples, case studies and published peer reviewed papers will be utilised, where possible. Minitab statistical software will be used.

### Module Assessment Strategies

Students will be required to complete two assignments.

### Repeat Assessments

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### Module Dependencies

**Prerequisites**

### Indicative Syllabus

**Review of Quantitative Tools - Incl. The Seven Tools of Quality**

Histogram*s:* How to prepare and use a Histogram. Mean, Mode, Median. Meaning of variation.

Cause and Effect Diagrams : Making CE diagrams. How to use CE diagrams.

Check Sheets: Function of check sheets. Types and uses of check sheets.

Graphs : Types of graphs. How to make and use graphs.

Pareto Analysis : How to make and use a Pareto diagram. Inclusion of cost on y-axis.

Scatter Diagrams:How to make and use a scatter diagram. The meaning of correlation

Boxplots : How to make and use boxplots. Comparing batches of data using boxplots.

Stem-and-Leaf Displays :How to make and use stem-and-leaf displays to see patterns in data.

**Review of Qualitative Tools **

Brainstorming and Nominal Group Technique.

Affinity diagram - gathering and grouping ideas

Interrelationship Diagrams - looking for drivers and outcomes

Radar Chart - rating organisation performance

Force Field Analysis - positives and negatives of change

Tree Diagram - Mapping the tasks for implementation

Prioritisation matrices - weighing options

**Control charts**

Introduction to Statistical Process Control. Review of Common cause and Special cause variation and X-bar and R variable control chart. Attribute control charts i.e. *p, np, c* and *u* charts. Individual *X* and Moving Range charts. Average Run Length, Short Run SPC, Standardised Run Charts - both attribute and variable. EWMA charts. Group charts and multiple stream processes. SPC for Low Defect Environments. Six Sigma and the DMAIC process. 3.4 ppm with a 1.5 standard deviation shift.

**Process and Guage Capability**

Review of Cp, Cpk, Cpm, Pp and Ppk. Calculation of capability and performance indices. Measurement Systems Analysis.. Gauge capability studies. The components of measurement error - repeatability and reproducibility. Precision-to-Tolerance ratio. Use of X-bar and R method for determining gauge capability. Combination of linear dimensions.

**Acceptance Sampling**

Principles of Acceptance sampling. Single sampling plans and their associated OC curves. Use of statistical tables to develop both the sampling plan and the OC curve. Calculation of OC curve etc. using cumulative Poisson tables.

Lot formation considerations. Single, and double sampling plans. Calculation of Average Sample Numbers (ASN). Average Outgoing Quality (AOQ and AOQL), Average Total Inspected (ATI).

**Sampling Standards**

Detailed focus on ANSI/ASQC Z1.4 (Acceptance Sampling by Attributes). Acceptance sampling by Variables - detailed focus on ANSI/ASQC Z1.9. Skip Lot sampling. Continuous Sampling plans. Chain Sampling.

### Coursework & Assessment Breakdown

**Coursework & Continuous Assessment**

**End of Semester / Year Formal Exam**

### Coursework Assessment

Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
---|---|---|---|---|---|---|

1 | Assignment work | Continuous Assessment | Assignment | 20 % | OnGoing | 1,2,3,4,5,6,7 |

### End of Semester / Year Assessment

Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
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1 | Final Exam - One written 2.5 hour paper | Final Exam | Closed Book Exam | 80 % | End of Term | 1,2,3,4,5,6,7,8 |

### Full Time Mode Workload

Type | Location | Description | Hours | Frequency | Avg Workload |
---|---|---|---|---|---|

Lecture | Not Specified | Lecture | 2 | Weekly | 2.00 |

Tutorial | Not Specified | Tutorial | 2 | Weekly | 2.00 |

Independent Learning | UNKNOWN | Independent Learning | 4 | Weekly | 4.00 |

### Part Time Mode Workload

Type | Location | Description | Hours | Frequency | Avg Workload |
---|---|---|---|---|---|

Lecture | Not Specified | Lecture | 2.5 | Weekly | 2.50 |

Tutorial | Not Specified | Tutorial | 0 | Weekly | 0.00 |

Independent Learning | UNKNOWN | Independent Learning | 4 | Weekly | 4.00 |

### Required & Recommended Book List

**Required Reading**

2013

*Statistical Quality Control*John Wiley & Sons

ISBN 1118322576 ISBN-13 9781118322574

This Edition continues to explore the modern practice of statistical quality control, providing comprehensive coverage of the subject from basic principles to state-of-the-art concepts and applications. The objective is to give the reader a thorough grounding in the principles of statistical quality control and a basis for applying those principles in a wide variety of both product and nonproduct situations. Divided into four parts, it contains numerous changes, including a more detailed discussion of the basic SPC problem-solving tools and two new case studies, expanded treatment on variable control charts with new examples, a chapter devoted entirely to cumulative-sum control charts and exponentially-weighted, moving-average control charts, and a new section on process improvement with designed experiments.

**Recommended Reading**

2018-10-24

*Statistical Process Control*Routledge

ISBN 1138064262 ISBN-13 9781138064263

The business, commercial and public-sector world has changed dramatically since John Oakland wrote the first edition of Statistical Process Control - a practical guide in the mid-eighties. Then people were rediscovering statistical methods of 'quality control' and the book responded to an often desperate need to find out about the techniques and use them on data. Pressure over time from organizations supplying directly to the consumer, typically in the automotive and high technology sectors, forced those in charge of the supplying production and service operations to think more about preventing problems than how to find and fix them. Subsequent editions retained the 'took kit' approach of the first but included some of the 'philosophy' behind the techniques and their use. The theme which runs throughout the 7th edition is still processes - that require understanding, have variation, must be properly controlled, have a capability, and need improvement - the five sections of this new edition. SPC never has been and never will be simply a 'took kit' and in this book the authors provide, not only the instructional guide for the tools, but communicate the management practices which have become so vital to success in organizations throughout the world. The book is supported by the authors' extensive and latest consulting work within thousands of organisations worldwide. Fully updated to include real-life case studies, new research based on client work from an array of industries, and integration with the latest computer methods and Minitab software, the book also retains its valued textbook quality through clear learning objectives and end of chapter discussion questions. It can still serve as a textbook for both student and practicing engineers, scientists, technologists, managers and for anyone wishing to understand or implement modern statistical process control techniques.

**Recommended Reading**

2011-08-02

*Statistical Methods for Quality Improvement*John Wiley & Sons

ISBN 9780470590744 ISBN-13 0470590742

"In this new edition, the author continues to explain how to combine the many statistical methods explored in the book in order to optimize quality control and improvement. The book has been thoroughly revised and updated to reflect the latest research and practices in statistical methods and quality control, and new features include: Updated coverage of control charts, with newly added tools. The latest research on the monitoring of linear profiles and other types of profiles Sections on generalized likelihood ratio charts and the effects of parameter estimation on the properties of CUSUM and EWMA procedures"--

**Recommended Reading**

2010-01-01

*Understanding Statistical Process Control*Spc Press

ISBN 0945320698 ISBN-13 9780945320692

### Module Resources

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