Manufacturing Engineering Applying Statistical Process Control (SPC) Copyright © Texas Education Agency, All rights reserved. 1

Bell Work Activity Directions: Please take out a sheet of paper and answer the following questions. A.Have you ever ordered a product and received the wrong item? What did you do to correct the problem? B.Why do you think this problem occurs between a business and it’s customers? (List three reasons.) 2 Copyright © Texas Education Agency, All rights reserved.

A. There are several important terms and definitions students need to know. B. Students will now complete the matching definitions handout on Applying Statistical Process Controls (SPC). Students may work in groups. Warm-up Activity Statistical Process Control (SPC) Terms 3 Copyright © Texas Education Agency, All rights reserved.

Understanding Variations with (SPC) Variations are defined as defects that occur in the work process. These defects can occur randomly or due to a specific cause. A random defect, like a lightning strike to a power line, that causes and electrical outage to a manufacturing plant, is difficult if not impossible to prevent. A specific cause defect, like using the incorrect ingredient in a cake mix, is preventable. 4 Copyright © Texas Education Agency, All rights reserved. DEFECTS

History of Statistical Process Control (SPC) SPC is a method of managing quality control within a work process. Many fundamental SPC principles were developed in the early 20 th century by Walter A. Shewhart, an American engineer. Later in the century W. Edwards Deming, an American statistician, continued to build on the work of Walter Shewhart and developed concepts to help improve the production of munitions manufacturing for companies during World War II. 5 Copyright © Texas Education Agency, All rights reserved.

Overview of Statistical Process Control (SPC) Statistical Process Control can be defined as the study of statistical data from a work process to gain an understanding of the cause of defective products (or variation). Then using this knowledge to put corrective actions in place to reduce or eliminate the defects and sustain the improvements through the life of the production cycle. …. 6 Copyright © Texas Education Agency, All rights reserved.

Process Mapping with (SPC) Before implementing SPC improvements, it is important to understand “how” a process works. Process mapping is done to identify key sequential steps in a work process on a visual flow chart. As the flowchart is created, improvements can be made to improve the process to reflect the most efficient method of completing overall work process. 7 Copyright © Texas Education Agency, All rights reserved. StartEndStep 1 Decision Step 2

Process Map Online Product Purchasing Process 1. Online product order from customer 2. Product manufactured by production 3. Product inspected by Quality Control; if defective, return to production for correction 4. Product packaged and sent to shipping department 5. Customer address verified 6. Customer payment verified or payment request created 7. Product sent to customer 8 Copyright © Texas Education Agency, All rights reserved. Start End Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7