What are some of the best practices and lessons learned from SPC projects?

1 Define the problem and the goal

Before starting an SPC project, it is essential to clearly define the problem and the goal of the project. What is the current state of the process? What are the customer requirements and expectations? What are the key performance indicators (KPIs) and the target values? How will the project align with the strategic objectives and vision of the organization? Defining the problem and the goal will help to scope the project, set the criteria for success, and communicate the purpose and benefits of the project to the stakeholders.

2 Select the appropriate SPC tools and techniques

SPC projects involve various tools and techniques, such as control charts, process capability analysis, Pareto analysis, cause-and-effect diagrams, histograms, scatter plots, and more. However, not all tools and techniques are suitable for every situation. Therefore, it is important to select the appropriate SPC tools and techniques based on the type, nature, and complexity of the data and the process. For example, control charts can be classified into different types depending on the type of data (variable or attribute), the subgroup size, and the distribution of the data. Choosing the wrong type of control chart can lead to erroneous conclusions and actions.

3 Involve and train the process owners and operators

One of the key factors for the success of SPC projects is the involvement and training of the process owners and operators. They are the ones who know the process best, who collect and analyze the data, who implement and sustain the improvements, and who monitor and control the process. Therefore, it is vital to engage them from the beginning, to solicit their input and feedback, to provide them with adequate training and coaching, and to recognize their efforts and achievements. By involving and training the process owners and operators, you can foster a culture of quality, ownership, and continuous improvement.

4 Validate and verify the data and the results

Data is the foundation of SPC projects. Without reliable and accurate data, you cannot measure, analyze, improve, or control the process. Therefore, it is crucial to validate and verify the data and the results of SPC projects. Validation means ensuring that the data is relevant, representative, and complete for the purpose of the project. Verification means ensuring that the data is collected, recorded, stored, and processed correctly and consistently. Some of the ways to validate and verify the data and the results are to use checklists, audits, sampling, testing, cross-checking, and peer review.

5 Implement and evaluate the improvements

The ultimate goal of SPC projects is to implement and evaluate the improvements that will enhance the quality and performance of the process. However, implementing and evaluating the improvements is not a one-time event, but a continuous cycle. It involves testing the changes on a small scale, measuring the impact, comparing the results with the baseline and the target, identifying the gaps and the root causes, making adjustments, and repeating the cycle until the desired outcome is achieved. It also involves documenting the changes, standardizing the best practices, and communicating the results and the benefits.

6 Monitor and control the process

The final step of SPC projects is to monitor and control the process to ensure that the improvements are sustained and that new problems are detected and corrected in a timely manner. This involves using control charts and other SPC tools to track the process performance over time, to identify any signals of variation or instability, to investigate any out-of-control or out-of-specification situations, and to take corrective or preventive actions. It also involves reviewing and updating the control limits, the process capability, and the KPIs periodically, and initiating new SPC projects when needed.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?